Molding apparatus

ABSTRACT

A process and an apparatus for molding, in which a molten thermoplastic resin is firmly fitted onto a molding surface of a mold under a pressure lower than or equal to 100 kg/cm2 and is cured to obtain a molded product. The molding apparatus has a mold main body, and a mold body on which the molding surface is defined. The mold body is supported relative to the mold main body with maintaining a space on the back side of the molding surface in a heat insulative manner by a supporting member which includes at least a heat insulative supporting member having a thermal conductivity of 0.001 to 1 Kcal/mh  DEG C. and a longitudinal elastic modulus of 0.01 to 10 kg/cm2. In the space, a heating fluid for heating the molding surface from the bask side to a temperature higher than or equal to Vicat softening temperate (T)  DEG C. of the thermoplastic resin and a cooling fluid for cooling the molding surface from the back side to a temperature lower than or equal to (Vicat softening temperature (T) of the thermoplastic resin -10)  DEG C. are supplied.

This application is a Division of application Ser. No. 08/620,455 filedon Mar. 22, 1996, now U.S. Pat. No. 6,048,189.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a molding apparatus and a process formolding with a thermoplastic resin. More specifically, the inventionrelates to a molding apparatus and a molding process which cansatisfactorily transfer a molding surface of a mold onto a moldedproduct in a short cycle time.

2. Description of the Related Art

As a method for obtaining resin molded products, an injection moldingprocess and a blow molding process are known.

The injection molding process is a system for injecting a molten resininto an enclosed mold at high pressure (200 to 1000 kg/cm²) to transferthe configuration of the molding surface of the mold onto the resin.Since this process employs high pressure, the configuration of themolding surface can be accurately transferred to the molded resin.Therefore, the injection molding process is suitable for molding aproduct having a highly smooth surface (hereinafter referred to as"mirror surface") or a grained surface. On the other hand, because ofhigh pressure employed, the mold withstanding high pressure becomesnecessary to make the constructure of the mold complicate to cause highcost. Therefore, the injection molding process is not suitable for aflexible manufacturing system. Also, since a special arrangement isrequired for forming a hollow product, it makes the production processcomplicate.

The blow molding process employs a system to supply a parison (hollowcylindrical resin in molten or softened condition) between mold halves,then clamp the mold halves, and to feed a fluid into a hollow portionunder pressure to urge the outer periphery of the parison onto themolding surface of the mold to transfer the configuration of the former.Since the parison is urged onto the molding surface by the fluidpressure, the pressure to be employed is relatively low (4 to 10kg/cm²). The configuration of the molding surface cannot be transferredaccurately onto the surface of the product. Therefore, the blow moldingprocess is not suitable for production of the molded product having amirror surface (highly smooth surface) or a grained surface. However,since the blow molding process is suitable for mass production of ahollow article, it is widely used.

Japanese Patent Application Laid-open No. 102734/1983 discloses a moldfor blow molding having an inner thin wall mold and an outer coolingmold which can be contacted and released to and from the inner mold. Inthis mold, for the purpose of improvement of the surface brilliance ofthe blow molded product, the mold is preliminarily heated beforesupplying of a parison. After the parison is brought into contact withthe molding surface of the inner mold, the inner surface of the outercooling mold is contacted onto the outer periphery of the inner mold toquickly cool the inner mold to obtain a molded product.

In Japanese Patent Application Laid-open No. 77231/1992, it is disclosedthat upon molding with contacting the parison onto the molding surfaceof a mold, a temperature of the mold is maintained within a range fromaround a temperature where crystallization speed of the parison becomesmaximum to a molten point thereof for preventing die-line or weld-linefrom being remained on the surface of the molded product. In addition,by circulating a coolant in the hollow of the parison during molding,expansion of a cycle time of molding is prevented.

Japanese Patent Publication No. 73903/1994 (corresponding to U.S. Pat.Nos. 5,017,126 and 5,190,715) discloses a mold for molding, in which ashell having a high thermal conductivity and having a large number ofcommunication holes, is fixed on a vessel-shaped mold frame to form acavity surface portion and an intermediate region at the backsidethereof. In the intermediate region, resin or metal having a low thermalconductivity is filled, or, in the alternative, a reinforcing blockhaving a communication hole is provided.

In the resin molding technology, there is a demand to obtain a resinmolded article having a mirror surface or a grained surface employing amold having a relatively simple construction. On the other hand, thereis a demand to produce a hollow molding article (e.g., air spoiler foran automotive vehicle) having a mirror surface or a grained surface, insimple process.

In the mold for a hollow article disclosed in the above mentionedJapanese Patent Application Laid-open No. 102734/1983, the moldingsurface is accurately transferred by heating the inner mold. However,since the resin is cooled by relatively shifting the inner mold relativeto the outer cooling mold, it is possible that the structure of the moldbecomes complicate and to be weak, and the cooling period becomeslonger. In this publication, there is no disclosure with respect to anoptimal heating temperature and/or cooling temperature for making thesurface of the molded resin article clear and for shortening an overallcycle time.

In the blow molding process disclosed in Japanese Patent ApplicationLaid-Open No. 77231/1992 above, it is intended to make the moldedsurface clear by heating the mold and maintaining the temperature of themold within a range from around a temperature where crystallizationspeed of the parison becomes maximum to a molten point thereof. In thisprocess, however, since the mold is maintained at this temperature evenduring a cooling period, it is not so effective to shorten the coolingperiod. Moreover, the parison is cooled from inside by circulating acoolant in the hollow of the parison, making the temperature controlcomplicate for maintaining the mold temperature at the abovetemperature.

The apparatus of Japanese Patent Publication No. 73903/1994 performsheating and cooling by passing a heating and cooling medium through aplurality of communication holes provided in inside and backside of theshell (mold surface portion) where the molding surface is formed, and byfeeding a heating and cooling medium within the intermediate region atthe backside of the molding surface. In the case of this apparatus,since heat transmission in the intermediate region is moderate, a cycletime can not be made shorter.

SUMMARY OF THE INVENTION

It is an object of the present invention to produce a molded resinarticle having a clear mirror surface or a grained surface with arelatively short cycle time.

Another object of the present invention to produce a molded resinarticle having a good surface quality through a relatively simpleprocess.

A further object of the present invention is to provide a mold which cansatisfactorily withstand to a pressure to be exerted on the moldingsurface by a molten resin and can provide sufficient durability withsatisfactorily long life of the mold, even if the mechanical strengthcannot be sufficient due to a relatively thin mold body forming themolding surface.

In a first aspect of the present invention, there is provided a moldingapparatus for obtaining a molded product by firmly fitting a moltenthermoplastic resin onto a molding surface of a mold under a pressurelower than or equal to 100 kg/cm² and curing, comprising:

a mold main body;

a mold body on which the molding surface is defined;

supporting means for supporting the mold body relative to the mold mainbody with maintaining a space on the back side of the molding surface ina heat insulative manner, the supporting means including at least a heatinsulative supporting member having a thermal conductivity of 0.001 to 1Kcal/mh °C. and a longitudinal elastic modulus of 0.01 to 10 kg/cm² ;

heating means for heating the molding surface from the bask side thereofto a temperature higher than or equal to Vicat softening temperate (T)°C. of the thermoplastic resin; and

cooling means for cooling the molding surface from the back side thereofto a temperature lower than or equal to (Vicat softening temperature (T)of the thermoplastic resin -10) °C.

The supporting means may include a sealing member for sealing the spacewith accommodating relative displacement between the mold body and themold main body due to the differences of thermal expansion.

The heating means may include means for supplying a heating medium intothe space at a given timing.

The heating means may include a heating fluid having modulus ofelasticity of volume of 1×10⁴ to 4.5×10⁴ kg/cm² the heating fluid beingsupplied into the space at a given timing and held therein.

A molding apparatus may further comprise:

control means for controlling introduction and discharge of a fluid intoand from the space, and

pressure control means for controlling pressure of the fluid in thespace corresponding to pressure to be exerted onto the molding surface,

The heating means may include a radiation heating device arranged at aposition in the space opposing to the back side of the molding surface.

A molding apparatus may further comprise:

at least one partitioning wall for dividing the space into a pluralityof spaces each including a part of the back side of the molding surfaceas an internal periphery, and

wherein the heating means heats the internal periphery of the dividedspaces independently,

A molding apparatus may further comprise:

first pressurized fluid supply means for supplying a pressurized fluidinto the space;

second pressurized fluid supply means for supplying a pressurized fluiddepressing the thermoplastic resin onto the molding surface the moldingsurface side; and

pressure adjusting means for following the pressure of one of thepressurized fluids to the pressure of the other pressurized fluid.

The cooling means may include means for supplying a cooling fluid intothe space at a given timing.

The cooling fluid may be a liquid state cooling medium, and furthercomprising:

means for forcedly removing the liquid state cooling medium depositingand residing on the back side of the molding surface in the space.

In a second aspect of the present invention, there is provided a blowmolding process employing a molding apparatus comprising:

a mold main body;

a mold body on which a molding surface is defined;

supporting means for supporting the mold body relative to the mold mainbody with maintaining a space on the back side of the molding surface ina heat insulative manner, the supporting means including at least a heatinsulative supporting member having a thermal conductivity of 0.001 to 1Kcal/mh °C. and a longitudinal elastic modulus of 0.01 to 10 kg/cm² ;

heating means for heating the molding surface from the bask side to atemperature higher than or equal to Vicat softening temperate (T) °C. ofa thermoplastic resin; and

cooling means for cooling the molding surface from the back side thereofto a temperature lower than or equal to (Vicat softening temperature (T)of the thermoplastic resin -10) °C., the process comprising the stepsof:

supplying a parison of a thermoplastic resin having a longitudinalelastic modulus at a temperature of (Vicat softening temperature (T)+100) °C. between the molding surfaces;

firmly fitting the outer surface of the parison onto the moldingsurfaces by applying a pressure less than or equal to 100 kg/cm² frominside of the parison;

elevating temperature of the molding surface at a temperature higherthan or equal to the Vicat softening temperature (T) °C. by heating themolding surface from the back side thereof by the heating means; and

cooling the molding surface down to a temperature lower than or equal to(Vicat softening temperature -10) °C. by cooling the molding surfacefrom the back side thereof by the cooling means.

The heating by the heating means may be performed simultaneously withfirm fitting of the parison onto the molding surface or after firmlyfitting of the parison onto the molding surface.

A blow molding process may further comprise a step of:

supplying a resin film between the parison and the molding surface.

In a third aspect of the present invention, there is provided a blowmolding process employing a molding apparatus comprising:

a mold main body;

a mold body on which a molding surface is defined;

supporting means for supporting the mold body relative to the mold mainbody with maintaining a space on the back side of the molding surface ina heat insulative manner, the supporting means including at least a heatinsulative supporting member having a thermal conductivity of 0.001 to 1Kcal/mh °C. and a longitudinal elastic modulus of 0.01 to 10 kg/cm² ;

heating means for heating the molding surface from the back side to atemperature higher than or equal to Vicat softening temperate (T) °C. ofa thermoplastic resin; and

cooling means for cooling the molding surface from the back side thereofto a temperature lower than or equal to (Vicat softening temperature (T)of the thermoplastic resin -10) °C., the process comprising the stepsof:

supplying a parison of a thermoplastic resin having a longitudinalelastic modulus at a temperature of (Vicat softening temperature (T)+100) °C. between the molding surfaces;

supplying a foaming component within the parison;

firmly fitting the outer surface of the parison onto the moldingsurfaces by applying a pressure less than or equal to 100 kg/cm² frominside of the parison;

elevating temperature of the molding surface at a temperature higherthan or equal to the Vicat softening temperature (T) °C. by heating themolding surface from the back side thereof by the heating means, and inconjunction therewith causing foaming of the foaming component; and

cooling the molding surface down to a temperature lower than or equal to(Vicat softening temperature -10) °C. by cooling the molding surfacefrom the back side thereof by the cooling means.

In a fourth aspect of the present invention, there is provided a blowmolding process employing a molding apparatus comprising:

a mold main body;

a mold body on which molding surfaces is defined;

supporting means for supporting the mold body relative to the mold mainbody with maintaining a space on the back side of the molding surface ina heat insulative manner;

heating means for heating the molding surface from the bask sidethereof;

cooling means for cooling the molding surface from the back sidethereof;

first pressurized fluid supply means for supplying a pressurized fluidinto the space;

second pressurized fluid supply means for supplying a pressurized fluidfor depressing a thermoplastic resin onto the molding surface to themolding surface side,

the process comprising the steps of:

supplying a parison of a thermoplastic resin between the moldingsurfaces;

firmly fitting the outer surface of the parison onto the moldingsurfaces by applying pressure of a fluid supplied Into the parison bythe second pressurized fluid supply means, and in conjunction therewithfollowing pressure of the fluid supplied from one of the first andsecond pressurized fluid supply means pressure of the fluid suppliedfrom the other of the first and second pressurized fluid supply means;

heating the molding surface from the back side by the heating means; and

cooling the molding surface from the back side by the cooling means.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood more fully from the detaileddescription given herebelow and from the accompanying drawings of thepreferred embodiment of the invention, which, however, should not betaken to be limitative to the present invention, but are for explanationand understanding only.

In the drawings:

FIG. 1A is a longitudinal sectional view showing a mold half of thefirst embodiment of the molding apparatus according to the presentinvention;

FIG. 1B is a longitudinal sectional view showing a mold half of thesecond embodiment of the molding apparatus according to the invention;

FIGS. 2A and 2B are longitudinal sectional views showing respective moldhalves of the third embodiment of the molding apparatus according to theinvention;

FIG. 2C is a longitudinal sectional view showing the fourth embodimentof the molding apparatus according to the present invention;

FIGS. 2D and 2E are longitudinal sectional views showing embodiments, inwhich a sensor for detecting a parison blowing pressure and a sensor fordetecting a pressure within a space are provided in the molds of FIGS.1A and 1B, respectively;

FIGS. 2F and 2G are longitudinal sectional views showing embodiments, inwhich a sensor for detecting a parison blowing pressure and a sensor fordetecting a pressure within a space are provided in the molds of FIGS.2A and 2B, respectively;

FIG. 2H is a longitudinal sectional view showing a mold half of thefifth embodiment of the molding apparatus according to the presentinvention;

FIG. 3A is a plan view showing a corner portion of the mold common toall of the embodiments;

FIGS. 3B, 3C, 3D and 3E are sectional views taken along line X--X ofFIG. 3A and showing a variety of modifications thereof, respectively;

FIGS. 4A, 4B, 4C and 4D are timing charts showing timings of respectiveprocess of the blow molding in examples 1, 4, 5 and 7, respectively;

FIGS. 5, 6 and 7 are flowcharts showing one example of control procedureof the fourth embodiment of the molding apparatus according to theinvention;

FIG. 8 is a block diagram showing a control circuit to perform theforegoing control;

FIGS. 9A, 9B, 9C, 9D and 9E are sectional views of the back side of themolding surface in the fifth embodiment of the molding apparatusaccording to the invention and showing various modifications thereof,respectively;

FIG. 10A is a longitudinal sectional view showing the sixth embodimentof the molding apparatus according to the invention;

FIG. 10B is a section taken along line B--B of FIG. 10A;

FIG. 11 is a longitudinal sectional view showing a mold half of theseventh embodiment of the molding apparatus according to the invention;

FIGS. 12A and 12B are graphs showing a relationship between the internalpressure of a parison and the pressure within the space of the mold, inthe seventh embodiment of the molding apparatus according to theinvention;

FIG. 13 is a graph showing variation of the pressure in the parison;

FIG. 14 is a graph showing variation of the pressure in the space of themold;

FIG. 15 is one modification of the seventh embodiment of the moldingapparatus of the invention;

FIG. 16 is another modification of the seventh embodiment of the moldingapparatus of the invention;

FIG. 17 is a sectional view showing a mold half of the eighth embodimentof the molding apparatus according to the invention;

FIGS. 18A, 18B, 18C and 18D are sections respectively showing moldhalves of the ninth embodiment of the molding apparatus of theinvention,

FIG. 19 is a timing chart showing a timing of respective step of themolding process;

FIGS. 20A, 20B, 20C and 20D are sections showing respective mold halvesof the tenth embodiment of the molding apparatus of the inventionshowing a sequence of the molding process, in order;

FIG. 21 is a timing chart showing a timing of respective step of themolding process;

FIG. 22A shows a modification of FIG. 18A;

FIG. 22B shows a modification of FIG. 21A;

FIG. 23A is a diagrammatic sectional view showing a condition of waterdeposited on the back side of the molding surface in the case wherecooling water is uniformly injected to the back side of the moldingsurface of the mold;

FIG. 23B is an explanatory illustration showing temperature measuringpoints of the molding surface;

FIG. 24 is a graph showing a temperature variation at respectivemeasuring points of FIG. 23B in the case where the molding surface isheated by injecting superheated steam from respective nozzles of themold of FIG. 23A and subsequently cooled by injecting cooling water fromrespective nozzles;

FIG. 25 is a diagrammatic illustration showing overall construction of ablow molding apparatus;

FIG. 26 is a sectional view showing a mold according to one aspect ofthe invention;

FIGS. 27 to 29 are diagrammatic sectional illustrations of a mold forrespectively explaining systems for heating the back side of the moldingsurface;

FIG. 30 is a diagrammatic sectional view showing a manner of heatingfrom the space side of the mold body where the molding surface of themold of FIG. 26 is formed;

FIGS. 31 and 32 are sections of molds for respectively explainingsystems for heating the molding surface;

FIG. 33 is a diagrammatic sectional view showing a manner of coolingfrom the space side of the mold body where the molding surface of themold of FIG. 26 is formed; and

FIG. 34 is a diagrammatic sectional illustration of the mold forexplaining a cooling system by evaporation of liquid.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiments of the present invention will be discussedhereinafter in detail with reference to the accompanying drawings. Inthe following description, numerous specific details are set forth inorder to provide a thorough understanding of the present invention. Itwill be obvious, however, to those skilled in the art that the presentinvention may be practiced without these specific details. In otherinstance, well-known structures are not shown in detail in order tounnecessarily obscure the present invention. It should be further notedthat like reference numerals refer to like elements throughout thedescription and the drawings.

FIG. 1A shows a mold half in the first embodiment of a molding apparatusconstituted of a pair of left and right mold halves according to thepresent invention. FIGS. 3A and 3B show details of a mounting structureat a corner portion of the mold half common to respective embodiments.Each mold half includes a shell-like mold body 3 having a moldingsurface 30 which defines a mold cavity and a main body 4 supporting themold body 3. It should be noted that both of the mold body 3 and themain body 4 are formed of stainless steel. A space B is defined betweenthe mold body 3 and the main body 4, namely between the back sidesurface of the molding surface 30 and the main body 4.

As shown in FIGS. 3A and 3B, a plate to be supported (hereinafterreferred to as a flange 36) extending from periphery of the mold body 3is loosely accommodated within a groove 46 provided in the main body 4corresponding thereto, with a play A. The mold body 3 is supported bythe main body 4 via a heat insulative support member 1 and a sealingmember. It should be noted that the groove 46 is formed by securing amain body panel 400 having an extended portion 400a onto a main bodybase portion 401 by means of a fastening bolt 403. On the other hand, asshown in FIG. 3A, at the end portions of each of four main body panels400 which are arranged into a quadrangular configuration as viewed fromthe above, with a clearance S of approximately 0.1 mm with respect toadjacent panel 400. Both opposing wall portions of the groove 46, a heatinsulation layer (heat insulative support member) 1 of a phenol resin ina thickness of 10 mm is provided. Also, in a clearance defined betweeneach of the front and back surfaces of the flange 36 and the heatinsulative supporting member 1 of the opposing both walls of the groove,an O-ring 9 is fitted. Therefore, even when the mold body 3 and the mainbody 4 thermally expand during molding of the molten resin resulting inrelative displacement between the flange 36 and the groove 46 suchdisplacement is accommodated with the play A. Therefore, harmfulinfluence (deflection, distortion or bending of the mold, shortening oflife and so forth) of the thermal expansion can be successfullyprevented. Therefore, precise molded products can be obtained. On theother hand, since the mold body 3 is supported on the main body 4 viathe heat insulative layer of the phenol resin satisfying a condition(material having longitudinal elastic modulus of 0.1×10⁴ to 100×10⁴kg/cm²) of the present invention, jolting or other nonconformity can beprevented.

The heat insulative supporting member 1 is formed of a material having athermal conductivity coefficient in a range of 0.001 to 1 kcal/mh °C.,preferably 0.005 to 0.8 kcal/mh °C., and more preferably in a range of0.01 to 0.5 kcal/mh °C., and a longitudinal elastic modulus of 0.1×10⁴to 100×10⁴ kg/cm², preferably 0.2×10⁴ to 40×10⁴ kg/cm², and furtherpreferably in a range of 1×10⁴ to 20×10⁴ kg/cm². Also, the heatinsulative supporting member 1 may be a laminated structure of amaterial having thermal conductivity coefficient in a range of 0.001 to1 kcal/mh °C., preferably 0.005 to 0.8 kcal/mh °C., and more preferablyin a range of 0.01 to 0.5 kcal/mh °C., and a material having alongitudinal elastic modulus of 0.1×10⁴ to 100×10⁴ kg/cm², preferably0.2×10⁴ to 40×10⁴ kg/cm², and further preferably in a range of 1×10⁴ to20×10⁴ kg/cm². Namely, any material of heat insulative supportingmaterial which can thermally insulate the mold body 3 and the main body4 and can certainly prevent jolt between the mold body 3 and the mainbody 4 against depression force to be exerted from the side of the moldbody 3 to the side of the main body 4.

It should be noted that reason of selection of the above-identifiedrange of the thermal conductivity coefficient of the heat insulativesupporting member 1, is that when the thermal conductivity coefficientis less than 0.001 kcal/mh °C., special material is required and thus isimpractical, and when the thermal conductivity coefficient exceeds 1kcal/mh °C., desired heat insulation effect cannot be obtained. Also,the reason why the above-identified range of the longitudinal elasticmodulus is selected is that if the longitudinal elastic modulus issmaller than 0.1×10⁴ kg/cm², stiffness becomes insufficient to make sealinsufficient, and when the longitudinal elastic modulus exceeds 100×10⁴kg/cm², processing of the heat insulating supporting portion becomesdifficult.

A material having thermal conductivity coefficient in the range of 0.001to 1 kcal/mh °C. and the longitudinal elastic modulus in the range of0.1×10⁴ to 100×10⁴ kg/cm², may be selected among polyarylate, polyetherether ketone, polyphenylene oxide, degenerated polyphenylene oxide,polyamide, acetal resin, ethylene tetrafluoride type resin, ceramics,PC, phenol resin, urea resin, melamine, glass unsaturated polyester andso forth, more preferably phenol resin, urea resin, melamine andunsaturated polyester, and further preferably phenol resin.

A space B defined between the back side of the mold body 3 and the mainbody 4 is sealingly closed by the O ring 9. Therefore, leakage ofheating steam or heating oil as a heating fluid supplied and filledthrough a valve 72, a piping 71 and a nozzle 70 in the space B duringheating, and cooling air or cooling oil filled similarly in the space Bduring cooling, through connecting portion of the mold body 3 and themain body 4 (portion where the mold body 3 is supported by the main body4, i.e. portion of the flange 36 and the groove 46), lowering of thepressure in the space B at the occurrence of the leakage above, anddistortion of the molding surface 30 caused by lowering of pressure, canbe successfully prevented.

In the above embodiment, O-ring is used as a sealing member, othermaterials, for example, a synthetic resin sheet, a synthetic rubbersheet, felt, leather, cork and so forth can be used. Moreover, since themold body 3 is heated up to Vicat softening temperature or more, it isrequired that these materials should withstand such temperatures.

It should be noted that while the O rings 9 as the sealing member aredisposed at both sides of the flange 36, it is possible to employ otherforms in combination with other sealing member. For example, as shown inFIGS. 3C and 3D, it is possible to form one with a sheet form sealingmember 9A. On the other hand, it is also possible to arrange the sheetform sealing members 9A at both sides of the flange 36, as shown in FIG.3E.

Furthermore, to the space B, heating medium or cooling medium areselectively supplied via the nozzle 70, the piping 71 communicated withthe nozzle, and the valve 72 openably closing the piping 71. On theother hand, heating medium or cooling medium is discharged via a piping76 and a valve 77 openably closing the piping 76.

It should be noted that, as shown in FIG. 3B in detail, a heatinsulation layer (heat insulation member) 2 consisted of a 10 mm thickphenol resin layer 22 and 2 mm thick asbestos layer 21 are provided onthe inner surface of the main body 4 facing the space B. Therefore,escaping of the heat of the heating medium in the space B through themain body 4 and penetration of the external heat to the cooling mediumthrough the main body 4, and other nonconformity can be avoided.Therefore, lowering of the temperature of the heating steam supplied tothe space B can be prevented to improve transfer ability of the moldingsurface and dimensional stability.

As the heat insulation member 2, polyarylate, polyether ether ketone,polyphenylene oxide, degenerated polyphenylene oxide, polyamide, acetalresin, ethylene tetrafludride type resin, ceramics, PC, phenol resin,urea resin, melamine, glass unsaturated polyester, asbestos, hardurethan form, rock wool, glass wool, calcium silicate, polystylene foam,water repellant pearlite, cork, wood (cedards), rubber, quartz glass,foamed beads and so forth, may be employed alone or in combinationtherewith. Preferably, phenol resin, urea resin, melamine, unsaturatedpolyester, asbestos, hard urethan form, foamed beads may be employed.

"First Example"

As a thermoplastic resin material, ABS45A (manufactured by JapanSynthetic Rubber Co., Ltd., Vicat softening temperature is 105° C.,longitudinal elastic modulus at 205 °C. is 0.3 kg/cm²) was employed, andas a blow molding apparatus, IPB-EP-55 (Ishikawajima Harima HeavyIndustries Co., Ltd.) was employed. Blow molding was performed at atiming of FIG. 4A under following conditions. Namely, the conditionswere:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Injected from Nozzle 70:                                                      Final Heating Temperature                                                                          140 to 150° C.                                    of Molding surface 30:                                                        Heating Holding Time 10 sec                                                   of Molding surface 30:                                                 (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Injected from Nozzle 70:                                               Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time of                                                                            60 sec                                                   Molding surface:                                                              All Cycle Time:      150 sec                                           ______________________________________                                    

Comparing a molded article (example) thus molded and a molded article(comparative example) molded without the above (4) heating of themolding surface 30, that is, without heating with supplying heatingsteam in the space B, in the example, the surface gloss value was 95%and curvature of the corner portion was less than or equal to 0.5, andin the comparative example, the surface gloss value was 20% and thecurvature of the corner portion was greater than or equal to 0.5.Namely, transferring performance of the molded product was better in theexample so that the molded article having smaller curvature at thecorner portion which could not be obtained in the conventional blowmolding was able to be accurately formed with high dimensionalstability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Article Dimension = 120(L) × 40(W) × 480(H)                ______________________________________                                        mm                                                                        

"Second Embodiment"

FIG. 1B shows the second embodiment of the mold. Hereinafter, aconstruction different from the first embodiment will be discussed andthe construction common to the first embodiment will be identified bythe same reference numerals and the detailed description thereof will beomitted.

The second embodiment is constructed by providing the halogen lamp 5mounted in the space B as a heating means in addition to the firstembodiment.

"Second Example"

Total output of the halogen lamp 5 was 60 kW (one side 30 kW), the finaltemperature of the molding surface 30 was the same as the first example.It should be noted that while injection of the heating steam is notperformed, in heating with the halogen lamp 5, 6 kg/cm² of air wasinjected from the nozzle 70 and the pressure in the space B was balancedwith the parison blowing pressure to be exerted from the side of themolding surface 30.

In this second example, the same effect was obtained as the firstembodiment in the surface gloss value and the curvature of the cornerportion.

"Third Example"

Injection molding was performed with employing the mold represented bythe equivalent diagrammatic illustration to FIG. 1A. Namely, as thethermoplastic resin, ABS15 (manufactured by Japan Synthetic Rubber Co.,Ltd., Vicat softening temperature is 100° C., longitudinal elasticmodulus at 200° C. is 0.2 kg/cm²) was employed, and as an injectionmolding apparatus, IS170FA3-5A (K. K. Toshiba Corporation) was employedto perform injection molding under the following conditions:

    ______________________________________                                        (1)    Cylinder Temperature:                                                                              210° C.                                    (2)    Gate: Side Gates at two positions                                      (3)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            pressure cf Heating Steam                                                     Injected from Nozzle 70:                                                      Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                    (4)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            pressure of (Cooling Water + Air)                                             Injected from Nozzle 70:                                                      Final Cooling Temperature of                                                                       50° C.                                            Molding surface 30:                                                    ______________________________________                                    

Comparing a molded article (example) thus molded with a molded article(comparative example) molded without Performing heating of the moldingsurface 30 of (3), the surface gloss value of the example was 95% andweld was not observed. In contrast to this, the comparative example hadthe surface gloss value of 85% and weld has been observed. Namely, theexample achieved higher surface transferring ability than thecomparative example, and achieved superior in avoidance of weld anddimensional stability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 400(L) × 400(W) × 350(H) mm             Molded Article Dimension = 50(L) × 3.2(W) × 80(H)                 ______________________________________                                        mm                                                                        

"Third Embodiment"

FIG. 2A is a structure providing a plurality of bar-shaped reinforcementribs 6 between the back surface of the mold body 3 and the inner surfaceof the main body 4 (surface opposing to the back surface 31 of the moldbody) in addition to the mold of FIG. 1A, for supporting at the backside of the mold body 3.

On the other hand, FIG. 2B is a structure providing a plurality ofbar-shaped reinforcement ribs 6 between the back surface of the moldbody 3 and the inner surface of the main body 4 (surface opposing to theback surface 31 of the mold body) in addition to the mold of FIG. 1B,for supporting at the back side of the mold body 3.

As set forth above, in the third embodiment, since reinforcement ribs 6are provided, even when the pressure of the heating steam or the coolingwater supplied into the space B through the valve 72, the piping 71 andthe nozzle 70 under pressure control, becomes smaller than the pressure(parison blowing pressure/injection pressure) applied from the moldsurface 30 side of the mold body 3, the mold body 3 can be supported toprevent deformation of the molded article due to distortion of themolding surface 30.

"Fourth Example"

As a thermoplastic resin material, ABS45A (manufactured by JapanSynthetic Rubber Co., Ltd., Vicat softening temperature is 105° C.,longitudinal elastic modulus at 205° C. is 0.3 kg/cm²) was employed, andas a blow molding apparatus, IPB-EP-55 (Ishikawajima Harima HeavyIndustries Co., Ltd.) was employed. Blow molding was performed at atiming of FIG. 4B under following conditions. Namely, the conditionswere:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Machine                                                   Oil filled in Space B:                                                        Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Cooling Machine                                                   Oil filled in Space B:                                                        Final Cooling Temperature                                                                          70° C.                                            of Molding surface 30:                                                        Cooling Holding Time 60 sec                                                   of Molding surface 30:                                                        All Cycle Time:      150 sec                                           ______________________________________                                    

It should be noted that the machine oil used for heating and cooling wasDuffny thermix oil from Idemitsu Kosan Co., Ltd.

Comparing a molded article (example) thus molded and a molded article(comparative example) without the above (4) heating of the moldingsurface 30, that is, without heating with filling a heating oil in thespace B, in the example, the surface gloss value was 95% and Curvatureof the corner portion was less than or equal to 0.5, and in thecomparative example, the surface gloss value was 20% and the curvatureof the corner portion was greater than or equal to 0.5. Namely,transferring performance of the molded article was better in the exampleso that the molded article having smaller curvature at the cornerportion which could not be obtained in the conventional blow molding wasable to be accurately formed with high dimensional stability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Article Dimension = 120(L) × 40(W) × 480(H)                ______________________________________                                        mm                                                                        

"Fourth Embodiment"

FIG. 2C shows an overall construction of the molding apparatus accordingto the present invention, constituted of a pair of left and right moldhalves. FIGS. 2D and 2E show the fourth embodiment of the mold, in whicha sensor 61 for detecting the blowing pressure of the parison P and asensor 62 for detecting the pressure within the space B are provided inthe mold shown in FIGS. 1A and 1B, respectively, and FIGS. 2F and 2Gshow the fourth embodiment of the mold, in which a sensor 61 fordetecting the blowing pressure of the parison P and a sensor 62 fordetecting the pressure within the space B are provided in the mold shownin FIGS. 2A and 2B, respectively.

"Fifth Example"

The mold shown in FIG. 2D and, as a thermoplastic resin material, ABS45A(Japan Synthetic Rubber Co., Ltd., Vicat softening temperature is 105°C., longitudinal elastic modulus at 205° C. is 0.3 kg/cm²) wereemployed, and as a blow molding apparatus, IPB-EP-55 (IshikawajimaHarima Heavy Industries Co., Ltd.) was employed. Blow molding wasperformed at a timing of FIG. 4C under following conditions. Namely, theconditions were:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Supplied to Space B:                                                          Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Supplied to Space B:                                                   Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time of                                                                            60 sec                                                   Molding surface 30:                                                           All Cycle Time:      150 sec                                           ______________________________________                                    

It should be noted that the pressure of the heating steam and theblowing pressure of the parison P were balanced by controlling openingdegree of the valves 72 and 77 on the basis of the detected values ofthe pressure sensors 61 and 62. Details will be discussed later.

Comparing a molded article (example) thus molded and a molded article(comparative example) without heating on the forming surface 30 of (4),namely, without heating with supplying heating steam in the space B, inthe example, the surface gloss value was 95% and curvature of the cornerportion was less than or equal to 0.5, and in the comparative example,the surface gloss value was 20% and the curvature of the corner portionwas greater than or equal to 0.5. Namely, transferring performance ofthe molded article was better in the example so that the molded articlehaving smaller curvature at the corner portion which could not beobtained in the conventional blow molding was able to be accuratelyformed with high dimensional stability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Article Dimension = 120(L) × 40(W) × 480(H)                ______________________________________                                        mm                                                                        

Next, along FIGS. 5 to 7, and with reference to FIG. 8, control of themold of the fourth embodiment will be discussed.

When a signal indicative of completion of injection of parison P isinput from an extruding machine 100, (Yes in step S11), a mold openingand closing mechanism is driven to initiate clamping of the mold (stepS13).

When clamping of the mold is completed (Yes in Step 14), a parisonblowing mechanism is driven to start blowing of air into the parison P,and a parison suction mechanism is also driven to start suction of theparison. In conjunction therewith, introduction of the heating steam isinitiated by opening of the valve 72 (step S15).

The parison suction mechanism is adapted to make the outer peripheralsurface of the parison with the molding surface 30 to firmly fitted witheach other for further improving configuration transferring ortranscripting ability. By providing not shown fine clearances on themolding surface 30, and vacuum aspiration of the air between the outerperipheral surface of the parison and the molding surface via theclearance is performed.

When the blowing pressure in the parison P reaching a predetermined setvalue (6 kg/cm² in this instance) is detected by the blowing pressuredetecting sensor 61 (Yes in step S16), a control for maintaining theblowing pressure in the parison P at the predetermined set value isinitiated (step S19). This control is for performing fine adjustment ofthe blowing pressure in the parison P and so forth so as to maintain theblowing pressure of the parison at the set value with monitoring thedetected value of the blowing pressure detecting sensor 61. Namely, whenthe blowing pressure in the parison is out of the set value in an amountexceeding a given value, the blowing mechanism for the parison is drivenin response thereto for controlling the pressure in the parison toincrease or decrease. It should be noted that if the pressure does notreach the set value even after expiration of sufficient period to reachthe blowing pressure in the parison P to the set pressure (No at stepS16 and Yes at step S17), it is regarded that certain abnormality iscaused in the blowing side to issue an alarm or so forth.

Next, when the pressure of the heating steam in the space B reaching apredetermined set value (6 kg/cm² in this case) is detected by means ofa pressure detecting sensor 62 in the space B (Yes at step S21), controlis initiated for maintaining the heating steam pressure in the space B(step S25) at the predetermined set value. In conjunction therewith, atimer for managing a heating continuing period (10 sec) is started (stepS27). The control at step S25 is for monitoring the detected value ofthe pressure detecting sensor 62 in the space B and to perform fineadjustment of the open degree of the valve 72 or so forth so as tomaintain the heating steam pressure at the set value. Namely, when thepressure in the space becomes cut of the set value to the extentexceeding a given value, the opening and closing mechanism and so forthfor the valve 72 is driven in response thereto for increasing ordecreasing the pressure within the space B. It should be noted that ifthe pressure of the heating steam in the space B does not reach the setvalue even after expiration of sufficient period to reach the heatingsteam pressure to the set pressure (No at step S21 and Yes at step S23),it is regarded that certain abnormality is caused in the heating steamsupplying system to issue an alarm or so forth.

When a given period managed by the heating timer which is started atstep S27 is expired (Yes at step S29), the control for maintaining thepressure of the heating steam in the space B at the set value isterminated. Then, the valve 77 is opened to discharge the steam in thespace B (step 31). Also, a steam and cooling water/air switchingmechanism is driven, and at the shame time, the valve 72 is opened toinitiate injection of cooling water toward the back surface 31 of themold body and introduction of the cooling air into the space B (stepS33).

On the other hand, when the pressure of the cooling air in the space Breaching the predetermined set value (6 kg/cm² in this instance) by thepressure detecting sensor 62 in the space B (Yes at step S35), a controlfor maintaining the pressure of the cooling air in the space B at theset value, is initiated (step 39), and a timer for managing the coolingcontinuing period (60 sec) is started (step 41).

The control at step S39 is to monitor the detected value of the pressuredetecting sensor 62 in the space B and to perform fine adjustment of theopen degree of the valve 72 or so forth so as to maintain the coolingair pressure in the space B at the set value. Namely, when the pressurein the space B becomes out of the set value to the extent exceeding agiven value, the opening and closing mechanism and so forth for thevalve 72 is driven in response thereto for increasing or decreasing thepressure within the space B. It should be noted that if the pressure ofthe cooling air in the space B does not reach the set value even afterexpiration of sufficient period to reach the heating steam pressure tothe set pressure (No at step S35 and Yes at step S37), it is regardedthat certain abnormality is caused in the cooling air supplying systemto issue an alarm or so forth.

Subsequently, when the pressure in the space B lowering down to a setvalue is detected by the pressure detecting sensor 62 (Yes at step 47),blowing into the parison P is terminated (step S49) and also sucking ofthe parison P is terminated (step S51).

In the manner set forth above, control of the mold of the fourthembodiment is performed.

It should be noted that the foregoing has been discussed in terms of acontrol system to perform blowing into the parison by transverseblowing. Namely, discussion has been given in terms of the control ofthe type, in which after completion of clamping of the mold (Yes at stepS14), blowing into the parison is initiated (step S15). However, thepresent invention should not be limited to the disclosed type ofcontrol. Namely, it is naturally applicable for the control system toblow into the parison by upward or downward blowing. In such a case,after completion of injection from the extruding machine, the lower endof the parison is sealed by pre-pinching, and then blowing into theparison may be initiated.

"Sixth Embodiment"

In the sixth embodiment, with employing the mold shown in FIG. 2D, andproviding a halogen lamp 5 in the space B, heating was performed. Totaloutput of the halogen lamp 5 is 60 kW (one side 30 kW). The finaltemperature of the molding surface 30 is the same as the foregoing fifthexample.

Even in the shown sixth example, equivalent effect to the fifth examplewas attained in terms of the surface gloss value and the curvature ofthe corner. Also, concerning the dimensional precision, sixth examplewas 5/1000 whereas the comparative example was 10/1000 or greater. Thus,the example exhibits higher precision.

As set forth above, the heating means according to the present inventioncomprises a nozzle 70 for supplying heating medium (heating oil, heatingair, steam or so forth) to the space B at back side of the moldingsurface 30, a piping for communication with the nozzle and a valve 72.It is possible to arrange a radiation heating means, such as a halogenlamp and so forth or other heating means within the space B. By heatingthe molding surface 30 at a temperature higher than or equal to Vicatsoftening temperature (T) °C. by the heating means, the configuration ofthe molding surface 30 can be clearly transferred or transcripted to thesurface of the resin. Thus a grained surface or a mirror surface of themolding surface 30 can be satisfactorily transferred.

The cooling means of the present invention may comprise the nozzle 70for injecting cooling air or cooling water to the back surface 31 of themolding surface 30 of the mold body 3, the piping 71 communicated withthe nozzle and the valve 72. By the cooling means, the molding surface30 can be quickly cooled down to a temperature lower than or equal to(Vicat softening temperature (T) -10) °C., the molded product can bequickly taken out to permit shortening of the molding cycle.

Introduction and discharge fluid into and from the space B can becontrolled by the valve 72 provided in the supply side piping 71 and thevalve 77 provided in the discharge side piping 76.

The control means of the present invention may be constructed with anelectronic circuit controlling opening and closing of two valves 72 and77 and a softwear implementing its function on the basis of the pressurein the space B and the pressure applied to the molding surface 30 fromthe molten resin. The means for detecting the pressure in the space B isnot necessary to directly detect the pressure in the space B but can bemeans for detecting the fluid pressure supplied to the space B. The sameis true even with respect to the detecting means for detecting thepressure to be exerted on the molding surface from the resin.

Moreover, the molding surface 30 of the mold is heated and cooled by amedium containing water as a component, the main body 4 and the moldbody 3 may be applied certain measure for corrosion inhibiting, ifdesired. As a measure, the material to form the main body 4 and the moldbody 3 may be selected among stainless, copper alloy, ceramics, aluminumalloy and so on which are difficult to rust. Preferably, stainless steelis employed. As another measure, treatment for making the surface of themetal non-conductive (e.g. nitrating treatment), coating of a corrosioninhibiting paint, or coating of a silicon type sol/gel type paint and soforth may be utilized.

While it is possible to heat the molding surface 30 before firmlyfitting the parison P on the molding surface, it is preferable to heatthe molding surface at the same timing or after fitting the parisonthereonto so that a needle for blowing gas into the parison can besmoothly inserted into the parison by fitting the parison onto themolding surface before heating at a temperature higher than or equal tothe Vicat softening temperature (T) °C. As a result, it becomes possibleto stably mold an article which has a mirror surface or a grainedsurface with high dimensional precision. It should be noted that thepreferred temperature of the molding surface upon fitting the parisonthereonto is in the range of the Vicat softening temperature (T) -20° C.to (T) -60 °C.

On the other hand, after completion of molding, the molded article maybe cured by cooling the molding surface down to the temperature lowerthan or equal to the Vicat softening temperature (T) -10° C.

The thermoplastic resin to be employed in the blow molding processaccording to the present invention has a property that the longitudinalelastic modulus is in a range of 0.01 to 10 kg/cm², preferably in arange of 0.05 to 2 kg/cm², and further preferably in a range of 0.1 to 1g/cm² at a temperature of the Vicat softening temperature (T) +100° C.

After supplying the hollow parison employing such thermoplastic resinbetween the molding surfaces, the external surface of the hollow parisonis depressed onto the molding surfaces under the pressure less than orequal to 100 kg/cm² for firm fitting and the pressure in the space B isconcurrently adjusted to balance with the depressing pressure. At thistime, preferably, in order to further improve transferring ability byfurther tightly fitting the external surface of the parison with themolding surface, the air between the parison and the molding surface isdischarged externally by vacuum sucking and so forth through fine gapsprovided in the molding surface, for example. Then, the molding surfaceis heated to the temperature higher than or equal to the Vicat softeningtemperature (T) °C., preferably higher than or equal to the Vicatsoftening temperature +5° C., more preferably higher than or equal tothe Vicat softening temperature +10° C., and further preferably higherthan or equal to the Vicat softening temperature +20° C., and thereafteris cooled at the temperature lower than or equal to the Vicat softeningtemperature -10° C., preferably lower than or equal to the Vicatsoftening temperature -20° C., and more preferably lower than or equalto the Vicat softening temperature -40° C.

It should be noted that the reason why the above-identified range of thelongitudinal elastic modulus at the temperature of Vicat softeningtemperature (T) +100° C. of the thermoplastic resin, is that if thelongitudinal elastic modulus is less than 0.01 kg/cm², draw down of theparison is caused to make it difficult to stably perform molding. On theother hand, if the longitudinal elastic modulus exceeds 10 kg/cm², alarge molding pressure becomes necessary for molding the parison, andfurther requires quite large blowing pressure for inflating the parisonto depress onto the molding surface.

The molding material suitable for such molding process, namely, thethermoplastic resin within a range of the longitudinal elastic modulus0.01 to 10 kg/cm² at a temperature of the Vicat softening temperature(T) +100° C., may be selected among, for example, AS resin, polystyrene,high impact polystyrene, graft co-polymer (ABS resin) consisted ofacrylonitrile-butadiene type rubber-styrene graft co-polymer(high-temperature ABS resin) consisted of acrylonitrile-butadiene typerubber-styrene-methylstyrene, graft co-polymer (AES resin) consisted ofacrylcnitrile-etylene-propylene type rubber-stylene and/or metacryl acidmethyl, graft co-polymer consisted of acrylonitrile-hydrogenated dienetype rubber-styrene and/or metacryl acid methyl, graft co-polymerconsisted of acrylonitrile-silicone rubber-styrene and/or metacryl acidmethyl, polyethylene, polyphenylene, poly carbonate, polyphenylen ether,polyoximethylene, nylon, metacryl acid methyl type co-polymer,polyethersulfon, polyarylate, vinyl chloride, co-polymer consisted ofmaleimide compound-styrene and/or acrylonitrile and/or a-methylstyrene,graft co-polymer consisted of rubber form co-polymer-maleimidecompound-styrene and/or acrylonitrile and/or metacryl acid methyl and/ora-methylstyrene, and their composition, and resin selected from theabove added a filler.

As the molded articles to be suitably molded by the molding processwould be housings, sporting products, playing tool, automotive products,furniture products, sanitary products, constructional products, kitchenproducts and so forth, for example. Furthermore, the molded product maybe a molded article having a foamed layer in the hollow portion a moldedarticle which is formed of the multi-layer blowing process, and a moldedarticle which is coated by plating, spattering, steam deposition orpainting and so forth.

As concrete examples, the housing may be a housing of a cooler box, atelevision set, an audio set, a printer, a facsimile machine, a copyingmachine, a gaming device, a washing machine, an air-conditioner, arefrigerator, a cleaner, an attache case, a musical instrument case, atool box, a container, a camera case and so forth.

As sporting products, a swimming board, a surfboard, a windsurfingboard, skis, a snow board, a skating board, an ice hockey stick, acarling ball, a game ball racket, a tennis racket, a canoe, a boat andso forth may be considered.

As playing tools, a bat, blocks, a building block, a fishing tacklecase, a pachinco base (pin ball) frame and so forth may be considered.

As automotive products, an air spoiler, a door, a bumper, a fender, ahood, a sun roof, a rear gate, a wheel cap, an instrument panel, a glovebox, a console box, an arm rest, a head rest, a fuel tank, a driver'sseat cover, a trunk tool box and so forth may be considered.

As furniture products, a drawer, a table top, a top and a bottom platesof a bed, a dresser frame panel, a shoe cupboard panel, and a frontdoor, a backboard and a bottom plate of a chair, a salver or a tray, anumbrella stand, a vase, a medicine chest, a hanger, a fancy box, astorage box board, a book stand, an office desk top, an officeautomation rack and so forth may be considered.

As sanitary products, a shower head, a lavatory seat, a lavatory panel,a water pan, a water tank lid, a basin door, a bath room door and soforth may be considered.

As constructional products, a ceiling board, a floor panel, a wallpanel, a window frame, a door, a bench and so forth may be considered.

As kitchen products, a cutting board, a kitchen door and so forth may beconsidered.

As molded products having a foamed layer in the hollow portion, a frontdoor of a refrigerator, a cooler box and so forth may be considered.

As molded products to be produced by the multi-layer blowing process, afuel tank and so forth can be considered.

As molded products coated by plating, spattering, steam deposition orpainting, for example, an exterior part for a vehicle, a housing for anelectronic device and so forth can be considered.

The foregoings are mere examples of the molded products. Therefore,naturally, the present invention is applicable for a variety of othermolded products.

"Fifth Embodiment"

FIG. 2H shows the fifth embodiment. In the shown embodiment, in order toimprove heat absorbing characteristics, surface treatment is provide forthe back surface 31 of the molding surface 30. Namely, on the backsurface 31, one of the surface treatments shown FIGS. 9A to 9E may beeffected.

FIG. 9A shows an example, in which heat absorption is enhanced by blackpainting (31a).

FIG. 9E shows an example, in which the surface area is increased byproviding a saw-teeth shaped surface configuration (31b).

FIG. 9C shows an example, in which the surface area is increased byproviding a grooved surface configuration (31c).

FIG. 9D shows an example, in which treatments (31d) in FIGS. 9A and 9Bare effected.

FIG. 9E shows an example, in which treatments (31e) in FIGS. 9A and 9Care effected.

On the other hand, at a position in the space B opposing to the backsurface 31 of the molding surface 30, the halogen lamp 5 of total output60 kW (30 kW at one side) as a radiation heating means is provided. Uponradiation heating of the back surface 31 by the halogen lamp 5, airhaving pressure of 6 kg/cm² is introduced into the space B through thevalve 72, the piping 71 and the nozzle 70 to balance with the parisonblowing pressure applied from the molding surface 30.

"Seventh Example"

The mold shown in FIG. 2H and, as a thermoplastic resin material, ABS45A(Japan Synthetic Rubber Co. Ltd., Vicat softening temperature is 105°C., longitudinal elastic modulus at 205° C. is 0.3 kg/cm²) wereemployed, and as a blow molding apparatus, IPB-EP-55 (IshikawajimaHarima Heavy Industries Co., Ltd.) was employed. Blow molding wasperformed at a timing of FIG. 4D under following conditions. Namely, theconditions were:

    ______________________________________                                        (1)   Extrusion Temperature: 220° C.                                   (2)   Clamping Force:        15 ton                                           (3)   Parison Blowing Pressure:                                                                            6 kg/cm.sup.2                                    (4)   Heating of Molding surface 30                                                                        6 kg/cm.sup.2                                          Radiation of Heating by Halogen lamp 5                                        Pressure of Air Injected from                                                 Nozzle 70 during Radiation Heating:                                           Final Heating Temperature of                                                                         150° C.                                         Molding surface 30:                                                           Heating Holding Time of                                                                              10 sec                                                 Molding surface 30:                                                     (5)   Cooling of Molding surface 30                                                                        6 kg/cm.sup.2                                          Pressure of (Cooling Water                                                    + Air) Injected from Nozzle 70:                                               Final Cooling Temperature of                                                                         70° C.                                          Molding surface 30:                                                           Cooling Holding Time of                                                                              60 sec                                                 Molding surface:                                                              All Cycle Time:        150 sec                                          ______________________________________                                    

A period to reach the temperature of the molding surface 30 at 150° C.in radiation heating by means of the halogen lamp 5 was measured.

Case of black painting of FIG. 9A: 25 sec

Case of black painting with Saw-teeth shaped surface of FIG. 9D: 20 sec

Case of no special treatment: 90 sec

It has been confirmed that elevation of temperature has become quickerby providing surface treatment for improving heat absorption on the backsurface 31 of the molding surface. Similarly, it has been confirmed thateven for the examples of FIGS. 9B, 9C and 9E, the required period toreach 150° C. could be shortened.

Comparing the molded article (example) thus molded and the moldedproduct (comparative example) molded without heating the molding surface30, in the example, the surface gloss value was 95% and curvature of thecorner portion was less than or equal to 0.5, and in the comparativeexample, the surface gloss value was 20% and the curvature of the cornerportion was greater than or equal to 0.5. Namely, transferringperformance of the molded product is better in the example so that themolded product having smaller curvature at the corner portion whichcannot be obtained in the conventional blow molding can be accuratelyformed with high dimensional stability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Product Dimension = 120(L) × 40(W) × 480(H)                ______________________________________                                        mm                                                                        

"Sixth Embodiment"

FIGS. 10A and 10B show the sixth embodiment according to the presentinvention. In the shown embodiment, a partitioning wall C dividing thespace B is provided. The partitioning wall C forms a plurality ofdivided spaces Ba, Bb, . . . by dividing the space B between the moldbody 3 and the main body 4. In respective divided spaces Ba, Bb, . . . ,respective part of the back surface 31 of the molding surface 30 areexposed. Each divided space Ba, Bb, . . . is desired to be thermallyinsulated with each other. Namely, it is desired to construct thepartitioning wall C by means of the previously mentioned heat insulativematerial.

In the shown embodiment, the partitioning wall C is constructed bysandwiching a phenol resin of 10 mm in thick as a heat insulativematerial between two metal (stainless steel) plates in thickness of 5mm. Namely, by employing the metal plates, even when a pressure isapplied to one of the divided spaces Ba, Bb, the partitioning wall maywithstand the pressure difference between the divided spaces Ba and Bb.By employing the heat insulative material, heat loss when heating steamis injected into one of the divided spaces Ba, Bb, can be avoided.

In the divided space Ba, heating steam or cooling water and air issupplied via a valve 72a, a piping 71a and a nozzle 70a, and in thedivided space Bb, heating steam or cooling water and air is supplied viaa valve 72b, a piping 71b and a nozzle 70b. The valves 72a and 72b areopened and closed independently of each other. Accordingly, it ispossible to supply heating steam to any one of the divided spaces Ba,Bb. In order to avoid concentration of stress, respective corners ofeach divided space are rounded with small curvature. The heating steam,cooling water, air supplied to divided space Ba and/or Bb is dischargedthrough the piping 76 and the valve 77 which is connected to the lowerportion of the respective divided spaces Ba and Bb in common.

Here, a product PV of the volume V of each divided spaces and thepressure P of the heating medium supplied to the divided space is setwithin a range of:

10 Kg.m≦PV≦2×10⁴ Kg.m

Preferably, the PV is

10 Kg.m≦PV≦1×10³ Kg.m

More preferably, the PV is

10 Kg.m≦PV≦4×10² Kg.m

Smaller PV results quicker elevation of pressure in the divided spacefor better heating efficiency. Conversely, at PV>2×10⁴ Kg.m, a longperiod of time is required for temperature elevation and cooling thedivided space, and temperature gradient may be caused to make itdifficult to uniformly mold the surface of the molded product.

By thus setting the PV, the mold of the present invention can beconstructed at relatively low cost and relatively low strength employinga material which can be utilized relatively easily.

"Eighth Example"

With employing the mold shown in FIGS. 10A and 10B, as a thermoplasticresin material, ABS45A (Japan Synthetic Rubber Co., Ltd., Vicatsoftening temperature is 105° C., longitudinal elastic modulus at 205°C. is 0.3 kg/cm²) was employed, and as a blow molding apparatus,IPB-EP-55 (Ishikawajima Harima Heavy Industries Co., Ltd.) was employed.Blow molding was performed at a timing of FIG. 4A under followingconditions. Namely, the conditions were:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure af Heating Steam                                                     Injected from Nozzle 70a, 70b:                                                Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Injected from                                                          Nozzles 70a, 70b:                                                             Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time of                                                                            60 sec                                                   Molding surface 30:                                                           All Cycle Time:      150 sec                                           ______________________________________                                    

Comparing the molded article (example) thus molded and the moldedproduct (comparative example) molded without the above (4) heating ofthe molding surface 30, in the example, the surface gloss value was 95%and curvature of the corner portion was less than or equal to 0.5, andin the comparative example, the surface gloss value was 20% and thecurvature of the corner portion was greater than or equal to 0.5.Namely, transferring performance of the molded product was better in theexample so that the molding product having smaller curvature at thecorner portion which could not be obtained in the conventional blowmolding was able to be accurately formed with high dimensionalstability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Product Dimension = 120(L) × 40(W) × 480(H) mm             Space Dimension of Ba, Bb = 70(L) × 70(W) × 500(H)                ______________________________________                                        mm                                                                        

In the above-mentioned example is the case where the overall moldingsurface 30 is heated by injecting heating steam into both of the dividedspaces Ba and Bb. When the similar molded product was molded by openingonly valve 72a to introduce the heating steam only into the dividedspace Ba to only partially heat the molding surface. The product had agood surface gloss value similarly to the foregoing example for theportion corresponding to the divided space Ba, whereas the portioncorresponding to the divided space Bb (portion not heated) had a surfacegloss value comparable with the comparative example. At the boundary,the surface gloss value varied gradually.

Namely, this means that, by controlling heating of the divided spaces Baand Bb independently, the product having a local gloss only at thedesired portion can be easily produced.

It should be noted that while the foregoing embodiment discloses thecase where the space B is divided into two, a molded product having goodquality similarly to the foregoing embodiment can be obtained bydividing the space into two to ten, preferably two to five. On the otherhand, by dividing the space, the volume of respective divided spaces canbe made small to set PV at a relatively small value. Therefore, partsfor a variety of members to be employed in production of the mold can beeasily obtained.

"Seventh Embodiment"

Next, discussion will be given for the seventh embodiment of the presentinvention. This embodiment is constructed for minimizing deformation ofthe mold body to obtain a molded product with high precision by makingone of the pressures of on the molding surface side and the back surfaceside to vary according to variation of the pressure on the other side.For this purpose, a fluid supply mechanism and a pressure adjustingmechanism are provided.

The fluid supply mechanism is a mechanism for supplying pressurizedfluid into the space on the back side of the molding surface and intothe parison on the molding surface side of the mold body, respectively,and comprises a fluid supply source and pipings. Respective fluid supplysources may be common or independent. Also, the fluid to be supplied tothe space on the back side of the mold body can be a medium for coolingor a medium for heating. As the cooling medium, cooling water, coolingair, cooling oil or so forth can be employed and as the heating medium,steam, heating air and so forth may be employed.

The pressure adjusting mechanism can be any mechanisms which can varyone of the pressures exerted onto a front surface side and a backsurface side of the mold body following to variation of the pressure onthe other side. Namely, the pressure adjusting mechanism may adjust thefluid pressure to be supplied into the parison on the front surface sideof the mold body following to variation of the pressure to be suppliedto the space on the back surface side of the mold body, or conversely,the pressure adjusting mechanism may adjust the fluid pressure to beintroduced into the space on the back surface side of the mold bodyfollowing to variation of the pressure to be introduced into the parisonon the front surface side of the mold body. The former case is generallyadvantageous for requiring a relatively simple mechanism. The reason isthat, since the steam has to be continuously supplied to the space onthe back surface side of the mold body for heating, and thus is requireda relatively long period of time to elevate the pressure in the space toa desired pressure level, whereas, since the parison is closed, theinternal air pressure thereof may be elevated to the desired pressurelevel in a relatively short period of time. Therefore, in order tosynchronize variation of the steam pressure to variation of the airpressure, a large scale mechanism becomes necessary and it is impossibleto simplify it. The pressure adjusting mechanism may be constructed, forexample, as shown in FIG. 11, by communicating the respective pipingsfor supplying pressurized fluid to the front side and the back side ofthe mold body 3 with each other. In such a case, an one-way check valvemay be provided for avoiding penetration of steam into the interiorspace of the parison.

On the other hand, in place of the communication of the pipings, it ispossible to make the pressure in the respective pipings to follow eachother by coupling the piping for supplying fluid on the front side ofthe mold body and the piping for supplying fluid to the space via acylinder with a piston displacably disposed therein for establishingbalance between the fluid pressure in both pipings.

Here, discussion will be given for the embodiment illustrated in FIG.11. In this embodiment, to the space between the back side of the moldbody 3 and the main body 4, steam in heating and cooling water orcooling air in cooling are supplied through a piping 50 and the nozzle70 from the supply source of the steam/cooling water/cooling air.

On the other hand, into the parison to be depressed onto the moldingsurface 30, air is supplied via a piping 55 from an air supply source.By this, the external surface of the parison is depressed onto themolding surface 30. The pressure of the air is followed by the fluidpressure to be supplied to the space B. Namely, the pipings 50 and 55are communicated via the one-way check valve 51 which blocks flow fromthe piping 50 to the piping 55. Therefore, by supplying air into theparison via the piping 55 from the air source, and in conjunctiontherewith, the steam at the equal pressure to the air pressure issupplied to the space B via the piping 50 from the steam supply source.Then, air flows from the piping 55 which takes up the pressure to thedesired level in a relatively short period, to the piping 50 which takesup the pressure in a relatively short period. As a result, the pressurein the space B can be taken up as shown in FIG. 12B, with followingvariation or elevation of the pressure in the parison as shown in FIG.12A.

The embodiment shown in FIG. 15 is mold different from that illustratedin FIG. 11. It should be noted that a piping system is illustrated foreasy understanding and is not necessary to be disposed in a section. Inthe mold shown in FIG. 15, the piping system is constructed such thatthe steam to be supplied to the space B on the back side of the moldbody 3 is also supplied into the parison on the molding surface side,thereby the pressure in the parison and the pressure in the space Bbeing synchronized.

Also, in the mold of FIG. 15, similarly to the embodiment shown in FIG.10B, the space B is divided into two sub-spaces Ba and Bb, and theheating vapor (steam) or cooling air may be supplied only to one ofdivided spaces Ba and Bb.

It should be noted that, in the case of the mold of FIG. 11, the similarpartitioning wall may be provided to divide the space B into a pluralityof divided spaces. This can be a measure for avoiding the pressuredifference between the divided spaces. Namely, the pressure differencecan be reduced by introducing the air in place of the steam in thedivided space, in which the steam is not introduced.

FIG. 16 shows the mold, according to this embodiment, which is slightlydifferent from FIGS. 11 and 15. The shown mold synchronizes the pressurein the piping 54 and the pressure in the piping 56 by disposing acylinder 57 having a movable piston 57a therein between the piping 54supplying steam into the space B on the back side of the mold body andthe piping 56 communicated with the piping supplying air into theparison on the front side of the mold body. By this, the pressure in thespace B and the pressure in the parison are equalized.

On the other hand, in the mold shown in FIG. 16, the space B is dividedinto two divided spaces Ba and Bb by the partition C, similarly to themold of FIG. 15.

"Ninth Example"

Employing the mold shown in FIG. 11, and at a timing shown in FIG. 12(horizontal axis of FIG. 12 is a time axis), steam air, and the coolingwater and the cooling air were selectively supplied. As a thermoplasticresin material, ABS45A (Japan Synthetic Rubber to., Ltd., Vicatsoftening temperature is 105° C., longitudinal elastic modulus at 205°C. is 0.3 kg/cm²) was employed, and as a blow molding apparatus,IPB-EP-55 (Ishikawajima Harima Heavy Industries Co., Ltd.) was employed.Blow molding was performed under following conditions. Namely, theconditions were:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Injected from Nozzle 70:                                                      Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Injected from Nozzle 70:                                               Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time ot                                                                            60 sec                                                   Molding surface 30:                                                           All Cycle Time:      150 sec                                           ______________________________________                                    

As a result, the pressure in the parison was varied as illustrated inFIG. 13, the pressure in the space B was varied as illustrated in FIG.14. Namely, both pressures exhibited quite high following ability toeach other, and the pressures in the parison and the space B could bemaintained at substantially the same pressure throughout all processsteps. Therefore, even when the thickness of the mold body 3 isrelatively thin, it can satisfactorily bear against the pressure to beexerted from the parison side. Also, since the thickness of the moldbody 3 can be made thin, reduction of weight and quicker heating andcooling from the back side of the molding surface, shortening of themolding cycle and excellent mirror surface finishing of the moldedproduct can be achieved.

Comparing the molded product (example) thus molded and the moldedproduct (comparative example) molded without heating the molding surface30 of (4), in the example, the surface gloss value was 95% and curvatureof the corner portion was less than or equal to 0.5, and in thecomparative example, the surface gloss value was 20% and the curvatureof the corner portion was greater than or equal to 0.5. Namely,transferring performance of the molded product was better in the exampleso that the molding product having smaller curvature at the cornerportion which had not been achieved in the conventional blow moldingprocess could be accurately formed with high dimensional stability.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Product Dimension = 120(L) × 40(W) × 480(H) mm             Space Dimension of Ba, Bb = 70(L) × 70(W) × 500(H)                ______________________________________                                        mm                                                                        

"Eighth Embodiment"

The eighth embodiment of the present invention will be discussed withreference to FIG. 17. The shown embodiment is adapted to form a resinfilm layer on the outer surface of a molded product.

The resin film F is supplied to be disposed between the molding surface30 and the outer periphery of the parison P. Namely, the film is fedfrom an upper roller and stretched between a lower roller to be disposedbetween the molding surface 30 and the parison P. The film F thussupplied is depressed onto the molding surface by the pressure of thefluid supplied into the parison P.

The resin film is selected depending upon the kind of the parison. Asthe resin film applicable for the present invention may be a low densitypolyethylene film, a medium density polyethylene film, a high densitypolypropylene film, a polypropylene film, lacquer type moistureproofingcellophane, polymer type moistureproofing cellophane, polyethylenecellophane, an acetate film, a soft polyvinyl chroride film, a hardpolyvinyl chroride film, a polyvinyl alcohol film, a polystyrene film, apolyester film, a rubber hydrochloride film and so forth, for example.

Next, discussion will be given for an embodiment which permits blowmolding of a resin product having an excellent mirror surface or agrained surface on the outer surface and having a foaming componentthere within through relatively simple process and in a relatively shortcycle time.

The foaming component employed in this invention consists of only afoaming agent or a combination of a forming agent and resin. In the caseof a foaming agent above it is used to expand a part of a parisonfoamed.

As a foaming agent, either a physical foaming agent or a chemicalfoaming agent may be used. As a physical foaming agent, inorganic typegas, such as air, carbon dioxide gas, nitrogen gas or so forth andorganic type gas, such as butane, pentane, hexane, fluon and so forthmay be used, for example. As a chemical foaming agent, an inorganic typeagent, such as sodium bicarbonate, bicarbonate, carbonate and so forth,and organic type, such as isocyanate compound, azo compound, hidrazinecompound, semicarbazide compound, azide compound, nitroso compound,triazole compound and so forth, for example, may be used.

As resin, thermosetting resin and thermoplastic resin may be applicable.As thermosetting resin, phenol resin, urea resin, epoxy resin,polyurethane and so forth may be considered, for example. Amongst, thepreferred thermosetting resin is polyurethane. On the other hand, asthermoplastic resin, styrene type resin (polystyrene ABS resin and soon), polyethylene, polypropylene, vinyl chroride resin, celluloseacetate, acryl type resin, fluoride resin, polyester, polyamide,polycarbonate and so forth may be considered, for example. Amongst, thepreferred thermoplastic resin is styrene resin. It should be noted thatthe resin may not be required to be resin before injection into theparison but should be resin after injection.

A method for supplying a foaming component to a parison may be selectedamong:

(1) a method for injecting it into a parison after formation of theparison;

(2) a method for injecting it into a parison enclosed in a mold; and

(3) a method for injecting it into a parison after the parison firmlyfits onto a molding surface.

A method for injecting a foaming component may be selected among:

(1) a method for forming a through hole from an outer surface of aparison to a hollow portion by an injection needle from the outersurface side of the parison and injecting the foaming component into thehollow portion;

(2) a method for injecting from the inside of a parison forming die;

(3) a method for utilizing a blowing device which firmly fits a parisononto a molding surface; and

(4) a method for utilizing a device supplying a heating fluid.

Foaming in a parison may be performed through the following processeslisted below, for example. These processes may be appropriatelycombined, if necessary.

(1) Elevating the temperature to be higher than or equal to Vicatsoftening temperature (T) °C. by heating the molding surface with aheating means so as to cause to foam utilizing the heat thus obtained;

(2) to foam by supplying heating fluid into the hollow portion of theparison; and

(3) to foam by reaction of the foaming component.

"Ninth Embodiment"

FIGS. 18A to 18D show a mold according to the ninth embodiment of thepresent invention and a sequence of a molding process. Also, FIG. 19shows timings at respective process steps of the molding process. Themold shown diagrammatically in FIGS. 18A to 18D includes a mold body 3having a molding surface 30, and a main body 4 supporting the mold body3. On the other hand, a space B is defined between the back side of themold body 3 and the main body 4. Also, a mechanism (comprising aninduction valve 72, a supply piping 71, an injection nozzle 70, adischarge piping 76 and a discharge valve 77) for injecting heatingsteam as a heating medium and cooling water or air as a cooling mediuminto the space B. It should be noted that the mold body 3 and the mainbody 4 are formed of stainless steel. Reference numeral 90 denotes anair supply source for blowing and 91 denotes a foaming component supplysource.

Here, discussion will be given for the sequence of the molding processemploying the mold as set forth above.

At first, as shown in FIG. 18A, the parison P is depended between bothmolding surfaces 30 of the mold halves. As shown in FIG. 18B, afterclosing the hollow portion, air is supplied from the air supply source90 to distend the parison P to firmly fit the outer surface of theparison P onto the molding surfaces 30. At the same time, a foamingcomponent (polyurethane type foaming component) P1 is supplied from thefoaming component supply source 91. Furthermore, heating steam isinjected into the space B on the back side 31 of the molding surfacefrom the nozzle 70.

By this, the parison P is heated up to the temperature higher than orequal to the Vicat softening temperature (T) °C. By this heating, thefoaming component P1 in the hollow portion of the parison P is foamed tospread over entirely in the hollow portion of the parison P, as shown inFIG. 18C.

Next, the heating steam in the space B is discharged through thedischarge piping 76 and the discharge valve 77. In conjunctiontherewith, the cooling water and the cooling air are injected into thespace B via the nozzle 70. By this, the parison P is quickly cooled downto the temperature lower than or equal to (Vicat softening temperature(T) -10) °C. On the other hand, after cooling, as shown in FIG. 18D, themold is opened and a molded product (having a mirror surface or agrained surface on the surface and a foamed layer inside) is taken out.

"Tenth Embodiment"

FIGS. 20A to 20D show a mold according to the tenth embodiment of thepresent invention and a sequence of a molding process. Also, FIG. 21shows timings at respective process steps. The mold showndiagrammatically in FIGS. 20A to 20D is substantially the same as thoseshown in FIGS. 18A to 18D, except for air supply source. Namely, in theshown embodiment, different from the molding process in the formerembodiment, air is not supplied to the parison P. The parison P isdepressed onto the molding surfaces 30 by the pressure of the foamingcomponent (polyurethane type foaming component) P1 supplied into thehollow portion in the parison P.

At first, as shown in FIG. 20A, the parison P depends between bothmolding surfaces 30. After closing the hollow portion shown in FIG. 20B,the foaming component (polyurethane type foaming component) P1 issupplied from the foaming resin supply source 91. Furthermore, heatingsteam from the nozzle 70 is injected into the space B on the back side31 of the molding surface.

By this, the parison P is heated up to the temperature higher than orequal to the Vicat softening temperature (T) °C. and the formingcomponent P1 in the hollow portion of the parison P foams. By thepressure of the foaming component, the outer surface of the parison P isdepressed onto the molding surfaces 30. Namely, as shown in FIG. 20C,the foamed foaming component P1 is spread over the entire area of thehollow portion of the parison P to depress the outer surface of theparison onto the molding surfaces. Here, foaming may be caused byheating from the back side 31 of the molding surface or by reaction ofthe foaming component P1 itself.

Next, the heating steam in the space B is discharged through thedischarge piping 76 and the discharge valve 77, the cooling water andthe cooling air are injected into the space B via the nozzle 70. Bythis, the parison P can be quickly cooled down to the temperature lowerthan or equal to (Vicat softening temperature (T) -10) °C. On the otherhand, after cooling, as shown in FIG. 20D, the mold is opened and amolded product (having a mirror surface or a grained surface outside anda foamed layer inside) is taken out.

A mold shown in FIG. 22A is a modification of the mold of FIGS. 18A to18D. In this modification, a communication piping 71a is branched fromthe piping 71 such that the steam to be supplied to the space B on theback side of the molding surface 30 is also supplied to the position Pon the molding surface side. By this, the pressure in the space B andthe pressure in the parison P are synchronized.

A mold shown in FIG. 22A, is another modification of the mold of FIGS.18A to 18D. In the modification, a cylinder 57 with a piston 57a isdisposed between a communication piping 71a branched from the piping 71supplying the steam into the space B on the back side of the moldingsurface 30, and a piping 90b communicated with a piping 90a supplyingthe air into the parison P on the molding surface side to synchronizethe pressure of the piping 90a and the pressure of the piping 71a. Bythis, the pressure in the space B and the pressure in the parison P aresynchronized.

"Tenth and Eleventh Example"

With each of the molds illustrated in FIGS. 18A to 18D and 20A to 20D,as a thermoplastic resin material, ABS45A (Japan Synthetic Rubber Co.,Ltd., Vicat softening temperature is 105° C., longitudinal elasticmodulus at 205° C. is 0.3 kg/cm²), as a forming component, polyurethanetype forming component and as a blow molding apparatus, IPB-EP-55(Ishikawajima Harima Heavy Industries Co., Ltd.) were employed. Blowmolding was performed under following conditions.

Namely, the conditions were:

Ninth Embodiment

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Injected from Nozzle 70                                                       (70a, 70b):                                                                   Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Injected from Nozzle                                                   70 (70a, 70b):                                                                Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time of                                                                            60 sec                                                   Molding surface 30:                                                           All Cycle Time:      150 sec                                           ______________________________________                                    

Tenth Embodiment

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Injected from Nozzle 70                                                       (70a, 70b):                                                                   Final Heating Temperature of                                                                       140 to 150° C.                                    Molding surface 30:                                                           Heating Holding Time of                                                                            10 sec                                                   Molding surface 30:                                                    (4)    Cooling of Molding surface                                                                         6 kg/cm.sup.2                                            Pressure of (Cooling Water                                                    + Air) Injected from Nozzle                                                   70 (70a, 70b):                                                                Final Cooling Temperature of                                                                       70° C.                                            Molding surface 30:                                                           Cooling Holding Time of                                                                            60 sec                                                   Molding surface 30:                                                           All Cycle Time:      150 sec                                           ______________________________________                                    

Comparing molded products (examples) thus molded according to the ninthand tenth embodiments, and molded products (comparative examples) moldedwithout heating the molding surfaces of the ninth and tenth embodiments,in the respective examples of the ninth and tenth embodiments, thesurface gloss value was 95% and curvature of the corner portion was lessthan or equal to 0.5, and in the respective comparative examples, thesurface gloss value was 20% and the curvature of the corner portion wasgreater than or equal to 0.5.

On the other hand, the foaming condition was that foaming is causeduniformly in entirety of the hollow portion of the molded products. Byinjecting the foaming resin into the hollow portion of the moldedproduct, the coefficient of thermal conductivity in the thicknessdirection of the molded product is 0.0278 kcal/mh °C. which iscomparable with the coefficient 0.0227 kcal/mh °C. of the sole foamingresin.

Namely, the examples exhibit better molding surface transferringperformance than the comparative examples. Also, the condition of thefoamed layer is satisfactorily good.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Molded Product Dimension = 120(L) × 40(W) × 480(H)                ______________________________________                                        mm                                                                        

Next, an embodiment which may improve energy efficiency in heating andcooling with shortening a cycle time and maintaining good moldingsurface transferring performance.

As shown in FIGS. 23A and 23B, through nozzles 701 to 705 which arearranged at substantially equal interval R in the vertical directionopposing the reverse side 31 of the molding surface 30, the coolingwater is supplied to the reverse side 31 of the molding surfaceuniformly. The cooling water supplied to the upper portion of thereverse side 31 falls down depositing on the surface 31 to reach thelower portion. As a result, about termination of cooling, as shown inFIG. 23A, the water film of the lower portion becomes thicker to presenta large amount of water in the lower portion. Therefore, the lowerportion can be excessively cooled. In addition, in the next heatingstep, since the large amount of water in the lower portion has to beremoved by evaporation and so forth, a large amount of thermal energyhas to be consumed. As a result, elevation of temperature at the lowerportion is delayed to cause temperature fluctuation of the moldingsurface 30.

FIG. 24 is a graph showing a result of measurement of temperatures ofthe molding surface 30 at four points, i e., at upper portion (rightupper corner, left upper corner: see FIG. 23B) and at relatively lowercentral portion (center, central right edge: see FIG. 23B) by means ofrespective thermocouples, when the cooling water is injected from thenozzles 701 to 705 through a piping 710 shown in FIG. 23A after heatingfrom the reverse side 31 of the molding surface 30 by injectingsuperheated steam from the nozzles 701 to 705 via the piping 710 (thecooling water is discharged from a piping 760). In the horizontal axis,the period of 6 to 96 sec is in heating state, 96 to 156 sec is incooling state, 156 to 189 sec is in air supplying state, 189 to 282 secis in heating state, 282 to 342 sec is in cooling state, and 342 andsubsequent period is in air supplying sate. It should be noted that eachof installation positions of respective thermocouples is within a holein the depth of about 5 mm formed at the back surface 31 of the moldingsurface 30. A thermocouple is also provided at the center of the moldingsurface 30 in order to make sure that a temperature in the hole issubstantially the same as that of a portion corresponding to the hole onthe molding surface side. This is illustrated as "center front surface"in the figure. As shown in the figure, it should be appreciated that the"center" and the "center front surface" shows substantially the sametemperature variation. The thickness between the front surface and theback surface of the mold body 3 is 10 mm.

As shown in FIG. 24, the center portion of the molding surface 30becomes lower temperature than the upper portion of the molding surface30 upon completion of cooling at the first cycle. Namely, the centerportion of the molding surface 30 is cooled to the temperaturesignificantly lower than the (Vicat softening temperature (T) -10) °C.This is considered for a thicker water film at the lower portion of thereverse 31 of the molding surface, as shown in FIG. 23A. On the otherhand, since the water may reside, elevating of the temperature in thenext heating step can be delayed. As a result, when the center portionof the molding surface 30 is heated to the Vicat softening temperature(T) °C., the upper portion of the molding surface 30 which has arelatively high temperature is elevated to the temperature far beyondthe Vicat softening temperature (T) °C. Also, this influence may appearin the next cooling step in an accumulative manner. Therefore, the upperportion of the molding surface 30 becomes more difficult to be cooled.

"Eleventh Embodiment"

To avoid the deficiencies set forth above, in the eleventh embodiment, agreater amount of cooling water is supplied to the upper portion of thereverse 31 of the molding surface 30 than the lower portion thereof soas to uniform the thickness of a water film. Moreover, a residualcooling medium disposed on the reverse of the molding surface isforcedly removed therefrom before heating.

A mold according to the eleventh embodiment is substantially the same asthe molds of the former embodiments except for having capability ofcontrol of the flow rate independently with respect to each of nozzles.

Accordingly, the mold shown in FIGS. 10A and 10B may be employed and thenozzles 70a, 70a', 70b, 70b' are controlled independently. Here, thenozzles 70a and 70b are located at the upper portion and the nozzles70a' and 70b' are located at the lower portion. In addition, in the airsupplying state set forth in connection with FIG. 24, by forcedlysucking air from the spaces Ba and Bb via the piping 76 by means of asuction pump or so forth, the water film depositing on the reverse 31 ofthe molding surface 30 can be removed.

On the other hand, it is desired to elevate the temperature to be higherthan or equal to the Vicat softening temperature (T) °C. withrestricting the temperature difference on the molding surface less thanor equal to 30° C., preferably less than or equal to 25° C., and furtherpreferably less than or equal to 20° C., and to cool down to thetemperature lower than or equal to (Vicat softening temperature (T) -10)°C. with restricting the temperature difference on the molding surfaceless than or equal to 40° C., preferably less than or equal to 30° C.,and further preferably less than or equal to 25° C. In order to achievethis, there are a method to supply a relatively greater amount of thecooling medium to the upper portion of the reverse of the moldingsurface, a method for forcedly removing the cooling medium depositing onthe reverse of the molding surface before the next heating step, and soForth. The foregoing may also be achieved by a method for dividing thespace on the back side of the molding surface into a plurality ofdivided spaces and adjusting the pressure of the heating medium and thecooling medium to be supplied to each of the divided spaces to permitconcentrically heating or cooling a certain region of the back surfaceof a molding surface, a method for selectively heating the portion wheretemperature is low by means of a radiation heating crevice, a method forlocally varying the thickness of the mold body to adjust the heatcapacity, and so forth. It should be noted that when a mechanism forinjecting high pressure superheated steam is employed as a heating meansand the space on the back side is divided into a plurality of dividedspaces, and when the superheated steam is injected into the dividedspace Ba (see FIG. 10B) and the superheated steam is not injected intothe divided space Bb, a pressure difference is caused between thedivided spaces Ba and Bb. Therefore, a partitioning wall provided fordividing the space B and thus defining the divided spaces Ba and Bb hasto withstand against the pressure difference. The partitioning wallsatisfying this requirement may be realized by a construction, in whicha heat insulation plate is sandwiched between two metal plates.

"Twelfth Example"

With employing the mold shown in FIGS. 10A and 10B, as a thermoplasticresin material, ABS45A (Japan Synthetic: Rubber Co., Ltd., Vicatsoftening temperature is 105° C., longitudinal elastic modulus at 205°C. is 0.3 kg/cm²) was employed, and as a blow molding apparatus,IPB-EP-55 (Ishikawajima Harima Heavy Industries Co., Ltd.) was employed.Then blow molding was performed.

Heating and cooling of the molding surface 30 of the mold was performedby controlling the nozzles 70a and 70b at the upper portion as a set andthe nozzles 70a' and 70b' at the lower portion as a set withindependently controlling injecting and not injecting the superheatedsteam or the cooling water and the cooling air independently per set.

The conditions were:

    ______________________________________                                        (1)    Extrusion Temperature:                                                                             220° C.                                    (2)    Clamping Force:      15 ton                                            (3)    Parison Blowing Pressure:                                                                          6 kg/cm.sup.2                                     (4)    Heating of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Heating Steam                                                     Injected from Nozzles 70a, 70b:                                               Pressure of Heating Steam                                                                          6 kg/cm.sup.2                                            Injected frcm Nozzles 70a', 70b':                                             Pressure of Heating Steam                                                                          6 kg/cm.sup.2                                            Injected from all Nozzles 70a,                                                70b, 70a', 70b':                                                              Final Heating Temperature of                                                                       140° C.                                           Molding surface 30 at                                                         the lowest temperature portion:                                               Heating Holding Time 10 sec                                                   of Molding surface 30:                                                 (5)    Cooling of Molding surface 30                                                                      6 kg/cm.sup.2                                            Pressure of Cooling Water                                                     and so forth Injected from Nozzles                                            70a, 70b:                                                                     Pressure of Cooling Water                                                                          6 kg/cm.sup.2                                            and so forth Injected from Nozzles                                            70a', 70b':                                                                   Pressure of Cooling Water                                                                          6 kg/cm.sup.2                                            and so forth Injected from                                                    all Nozzles 70a, 70b, 70a', 70b':                                             Final Cooling Temperature                                                                          70° C.                                            of Molding surface 30 at                                                      the highest temperature portion:                                              Cooling Holding Time 60 sec                                                   of Molding surface 30:                                                 ______________________________________                                    

(A) Sample A was molded by injecting superheated steam through all ofthe nozzles 70a, 70b, 70a' and 70b' in the heating step and by injectingcooling water and so forth only through the nozzles 70a and 70b at theupper portion in the cooling step. In this case, a required period inthe heating step in the second and subsequent cycles was about 57 secwith the temperature difference during the heating step less than orequal to 17° C., and a required period for the cooling step wad about 53sec with the temperature difference during the cooling step less than orequal to 13° C. Also, a necessary period for one cycle was about 140sec. Here, the required period in the heating step is a period requiredfor elevating the temperature at the lowest temperature portion to 140°C., and the required period in the cooling state is a period requiredfor lowering the temperature at the highest temperature portion down to70° C. This would be same in all of the following examples.

(B) Sample B was molded by injecting superheated steam through call ofthe nozzles 70a, 70b, 70a' and 70b' in the heating step, and byinjecting cooling water only through the nozzles 70a and 70b at theupper portion, subsequently injecting only cooling air and inconjunction therewith forcedly removing the cooling water by sucking theair through the piping 76 in the cooling step. In this case, therequired period in the heating step in the second and subsequent cycleswas about 47 sec with the temperature difference during the heating stepless than or equal to 12° C., and the required period for the coolingstep wad about 44 sec with the temperature difference during the coolingstep less than or equal to 10° C. Also, the necessary period for onecycle was about 121 sec.

(C) Sample C was molded by injecting superheated steam through thenozzles 70a' and 70b' at the lower portion in the heating step and byinjecting cooling water and so forth only through the nozzles 70a and70b at the upper portion. In this case, the required period in theheating step in the second and subsequent cycles was about 62 sec withthe temperature difference during the heating step less than or equal to22° C., and the required period for the cooling step was about 53 secwith the temperature difference during the cooling step less than orequal to 16° C. Also, the necessary, period for one cycle was about 145sec.

(D) Sample D was molded by injecting superheated steam through thenozzles 70a' and 70b' at the lower portion in the heating step, and byinjecting cooling water only through the nozzles 70a and 70b at theupper portion, subsequently injecting only cooling air and inconjunction therewith forcedly removing the cooling water by sucking theair through the piping 76 in the cooling step. In this case, therequired period in the heating step in the second and subsequent cycleswas about 56 sec with the temperature difference during the heating stepless than or equal to 15° C., and the required period for the coolingstep was about 51 sec with the temperature difference during the coolingstep less than or equal to 12° C. Also, the necessary period for onecycle was about 137 sec.

(E) Comparative sample E was molded by injecting superheated steamthrough all of the nozzles 70a, 70b, 70a' and 70b' in the heating stepand by injecting cooling water and so forth through all of the nozzles70a, 70b, 70a' and 70b' in the cooling step. In this case, the requiredperiod in the heating step in the second and subsequent cycles was about83 sec with the temperature difference during the heating step less thanor equal to 34° C., and the required period for the cooling step wadabout 77 sec with the temperature difference during the cooling stepless than or equal to 50° C. Also, the necessary period for one cyclewas about 190 sec.

As set forth above, while molding of samples A to D could be done with arelatively short period, molding of comparative sample E required a muchlonger period than samples A to D. Comparing with each of samples, boththe molded samples A to D and the comparative sample E had good qualitythat the surface gloss value was 95% and curvature of the corner portionwas less than or equal to 0.5. Namely, transferring performance of themolded product was satisfactory in all of the samples A to D and thecomparative sample E in that the molded product having smaller curvatureat the corner portion which had not been obtained in the conventionalblow molding was able to be accurately formed with high dimensionalstability.

However, in the case of the molding process of the comparative sample E,when the period of the heating step was shortened as in the samples A toD, the final temperature at the lowest temperature portion of themolding surface could not reach 140° C., resulting in causing poortransferring portions on the surface of the molded product.

Also, in the case of the molding process of the comparative sample E,when the period of the cooling step was shortened as in the samples A toD, the final temperature at the highest temperature portion of themolding surface could not be cooled down to 70° C., resulting in causinga failure in taking out the molded product.

It should be noted:

    ______________________________________                                        Mold External Dimension = 460(L) × 560(W) × 720(H) mm             Product Dimension = 120(L) × 40(W) × 480(H)                       ______________________________________                                        mm                                                                        

"Other Examples"

Further discussion will be given for other examples of the presentinvention and comparative examples. In the following examples and thecomparative examples, ABS resin is used as a thermoplastic resin. Thethermoplastic resin material is ABS45A (Japan Synthetic Rubber Co. Ltd.,Vicat softening temperature is 105° C., longitudinal elastic modulus at205° C. is 0.3 kg/cm²).

In the following examples and the comparative examples, blow molding isperformed employing ABS resin (JSR ABS45A) to form a box-shaped moldedproduct. Namely, in each of examples and the comparative examples, asshown in FIG. 25, ABS resin is molten and fed into an accumulator die 82by means of an extruder 81. In the accumulator die, a hollow cylindricalparison P is formed and fed downwardly. The parison P is then set in oneof the mold 3 (examples A to C, comparative examples a to e) to performblow molding.

Here, a screw diameter of the extruder 81 is 55 mm and a maximumextruding capacity is 2000 cc. On the other hand, a diameter of theparison fed out from the accumulator die 82 is 100 mm and temperaturethereof is 200° C. The feeding period to the mold 3 is 2 sec in anycase. Also, the width of the mold is 250 mm and the height thereof is600 mm, and the thickness is 50 mm. The maximum clamping force to beexerted on the mold is 15 tons. The molding surfaces of respective moldhalves are mirror surfaces.

On the other hand, upon initiation of blow molding, in any of the mold,by maintaining a vacuum degree of 30 mmHg for ten seconds between theparison P and the molding surface of the mold 3, the outer periphery ofthe parison is contacted to or placed in the vicinity of the moldingsurface by suction force. During this, an air feeding needle disposed ina mold cavity is inserted into the parison. By continuing feeding of airunder the pressure of 7 kg/cm² into the interior hollow space of theparison P the outer periphery of the parison is firmly fitted onto themolding surface of the mold. Namely, with setting the molding or blowingpressure at 7 kg/cm², molding is performed. It should be noted that theclamping force was 15 tons for all the cases.

Next, discussion will be given for different conditions and so forthwith respect to each mold.

Example A

In this mold, heating was performed by the system illustrated in FIG. 28and cooled by the system illustrated in FIG. 34. Namely, for the moldbodies 3a and 3b having the molding surface temperature at 50 °C., theouter periphery of the parison P was firmly fitted. Then, the moldingsurface of the mold bodies 3a and 3b were heated to 120° C. by heatgeneration bodies (electric heaters) 50a and 50b provided in respectivespaces BA and BB defined between the mold bodies 3a and 3b and the mainbodies 4a and 4b, and abutting the heat generating bodies 50a and 50bonto the back surfaces of the mold bodies 3a and 3b by the action ofhydraulic cylinders 50a1 and 50b1 via rods 50a2 and 50b2. Also,respective heat generating bodies 50a and 50b were retracted to theinitial positions respectively by the action of the hydraulic cylinders50a1 and 50b1 during cooling. It should be noted that, in FIG. 28, 1aand 1b denote heat insulating bodies.

On the other hand, after firmly fitting the outer surface of the parisonP onto the molding surfaces of the mold bodies 3a and 3b, cooling water(pressurized water) was injected into the spaces BA and BB through thepipings 71a and 71b, The flow rate of the cooling water was 100 cc/sec.Also, the injecting direction was the (direction toward the back surfaceof the mold bodies 3a and 3b. By this, heat exchange was caused at theback surface to evaporate the cooling water and at the same time, themold bodies 3a and 3b were cooled. The cooling period was 30 sec. On theother hand, the steam was sucked and discharged through the pipings 76aand 76b by a vacuum pump P0. Namely, the spaces BA and BB were in thevacuum condition to promote evaporation of the cooling water.

After cooling, ventilation of gas in the molded product was performedand the product was taken out after opening or unclamping the mold. Atthis time, transferring condition of the mirror surface was quite good.Also, the product did not contain bending or warp and exhibited highdimensional precision. A necessary period up to taking out of the moldedproduct was 60 sec and the overall cycle time was 70 sec. With the caseof the mold having a grained pattern on the molding surface, like resultwas obtained.

Example B

In this mold, heating was performed by the system illustrated in FIG. 29and cooled by the system illustrated in FIG. 33. Namely, for the moldbodies 3a and 3b having the molding surface temperature at 50 °C., theouter periphery of the parison P was firmly fitted. Then, as shown inFIG. 29, by means of line condensing type heaters 51a and 51b providedin respective spaces BA and BB, heat was radiated onto the back surfaceof the mold bodies 3a and 3b to heat the molding surface to 120° C.,respectively. It should be noted that this heating was stopped after 2sec from initiation of feeding of air into the parison P.

After termination of heating by means of the line condensing typeheaters 51a and 51b, air at the temperature of -10° C. was fed at a flowrate of 50 l/min into respective spaces BA and BB via the pipings 71aand 71b, as shown in FIG. 33. Feeding of the air was performed by meansof dispersing nozzles so that the air was injected toward the backsurface of the mold bodies 3a and 3b. Thus, heat exchange was caused atthe back surface to cool the mold bodies 3a and 3b from the back side.It should be noted that the air fed into respective spaces BA and BBwere discharged via the pipings 76a and 76b after heat exchanging.

After cooling, gas ventilation was performed in the molded product andthe product was taken out after opening the mold. The product exhibitedexcellent mirror surface transfer performance. Also, the product did notcontain bending or warp and exhibited high dimensional precision. Anecessary period up to taking out of the molded product was 110 sec. Onthe other hand, the overall cycle time was 130 sec. With the case of themold having a grained pattern on the molding surface like result wasobtained.

Example C

In this mold, heating was performed by the system illustrated in FIG. 27and cooled by the system illustrated in FIG. 34. Namely, for the moldbodies 3a and 3b having the mold surface temperature at 50 °C., thecuter periphery of the parison P was firmly fitted. Then, as shown inFIG. 27, heating steam of the temperature of 150° C. is injected towardthe back surface of the mold bodies 3a and 3b via the pipings 71a and71b. By this, heat exchange was caused on the back surface of the moldbodies 3a and 3b to condense the heating steam to be droplets, and inconjunction therewith, the front surface side (the molding surface) ofthe mold bodies 3a and 3b) was heated to 120° C., respectively. Itshould be noted that the droplets were discharged from the pipings 76aand 76b via the pressure modifying valves 77a and 77b.

After terminating heating by the heating steam of the temperature of150° C., the mold bodies 3a and 3b were cooled down to 80° C. by thesystem shown in FIG. 34.

After cooling, gas ventillation was performed in the molded product andthe product was taken out after opening the mold. The product exhibitedexcellent mirror surface transfer performance. Also, the product did notcontain bending or warp and exhibited high dimensional precision. Anecessary period up to taking out of the molded product was 65 sec. Onthe other hands, the overall cycle time was 75 sec. With the case of themold having a grained pattern on the molding surface, like result wasobtained.

Comparative Examples

Respective molds of the comparative examples a to e have constructions,in which the molding surface was integral with the main body.Accordingly the molds had, no heat insulation body. Therefore, when themold was heated for clearly transferring the molding surface, a longperiod was required for cooling.

The temperature of respective molds upon molding was 50° C. in thecomparative example a, 120° C. in the comparative example b, 170° C. inthe comparative example c, 30° C. in the comparative example d and 150°C. in the comparative example e. Namely, the comparative examples a andd were low temperature and the comparative examples b, c and e were hightemperature.

Therefore, the condition of the mirror surface of respective moldedproducts was ordinary in the comparative example a which was heated atmedium temperature, excellent in the comparative examples b, c and ewhich were heated at high temperature, and unacceptable in thecomparative example d which was heated at low temperature.

On the other hand, the required period to take out the molded productand overall cycle time were respectively, 60 sec and 70 sec in thecomparative example a which was heated at medium temperature, 150 secand 170 sec in the comparative example b which was heated at hightemperature, 290 sec and 310 sec in the comparative example c which washeated at high temperature, 45 sec and 55 sec in the comparative exampled which was heated at low temperature, and 250 sec and 280 sec in thecomparative example e which was heated at high temperature. Namely,higher temperature requires longer period to take out the products andlonger overall cycle time, and opposite to the condition of the mirrorsurface.

As set forth, in the molds in the comparative examples, though themirror surface can be transferred satisfactorily by heating at hightemperature, it inherently causes a problem of long period required fortaking out the products and long overall cycle time.

Similar results were obtained in molding the products having the grainedsurfaces.

It should be noted that the comparative example f was molded by firmlyfitting the parison after heating the molding surface at 120° C. in themolding process of example A. Subsequent process were the same as thatof the example A. Obtained product was lower than the example A inmirror surface transferring ability, anti-bending ability, dimensionalprecision and molding stability.

Other Examples

While the foregoing discussion with respect to the examples A to C hasbeen given for the systems illustrated in FIGS. 27, 28, 29, 33 and 34,it is further possible to heat by systems illustrated in FIGS. 30 to 32.FIG. 30 is a system to heat the molding surface by supplying the heatinggas via the pipings 71a and 71b and ventilating the gas through thepipings 76a and 76b after heat exchange. FIG. 31 is a system to heat themolding surface by temporarily inserting the line condensing typeheaters 51a and 51b on the molding surface side of the mold bodies 3aand 3b. Also, FIG. 32 is a system to heat the molding surface bytemporarily inserting air supply pipes 53a and 53b on the moldingsurface side of the mold bodies 3a and 3b.

In addition to the foregoing heating systems, a system for heating byemploying high frequency, a system for heating by employing a farinfrared light and so forth may be used. Also, as a method for obtainingsteam for heating, an induction heating system may be used.

Although the invention has been illustrated and described with respectto exemplary embodiment thereof, it should be understood by thoseskilled in the art that the foregoing and various other changes,omissions and additions may be made therein and thereto, withoutdeparting from the spirit and scope of the present invention. Therefore,the present invention should not be understood as limited to thespecific embodiment set out above but to include all possibleembodiments which can be embodies within a scope encompassed andequivalents thereof with respect to the feature set out in the appendedclaims.

What is claimed is:
 1. A controlling apparatus for controlling moldingconditions for a molding apparatus obtaining a molded product by firmlyfitting a molten thermoplastic resin onto a molding surface of a moldunder a pressure lower than or equal to 100 kg/cm² and curing, saidmolding apparatus comprising:a mold main body; a mold body on which saidmolding surface is defined; and a space defined between said mold mainbody and said mold body on the back side of said molding surface; saidcontrolling apparatus comprising:means for controlling introduction anddischarge of a fluid into and from said space; pressure control meansfor controlling pressure of said fluid in said space corresponding topressure to be exerted onto said molding surface, wherein said pressurecontrol means comprises first pressure control means for controlling apressurized fluid supplied into said space; second pressure controlmeans for controlling a pressurized fluid depressing said thermoplasticresin onto said molding surface supplied on said molding surface side;and pressure adjusting means for following the pressure of one of saidpressurized fluids to the pressure of the other pressurized fluid; heatcontrol means for controlling heating said molding surface from saidspace on the back side of said molding surface to a temperature higherthan or equal to Vicat softening temperature (T) °C. of saidthermoplastic resin; and cooling control means for controlling coolingsaid molding surface from said space on the back side of said moldingsurface to a temperature lower than or equal to (Vicat softeningtemperature (T) of said thermoplastic resin -10) °C.
 2. A controllingapparatus as claimed in claim 1, wherein said controlling heatingincludes supplying a heating fluid into said space at a given timing. 3.A controlling apparatus as claimed in claim 1, wherein said heating isperformed by supplying heated air into said space.
 4. A controllingapparatus as claimed in claim 1, wherein said heating is performed bysupplying steam into said space.
 5. A controlling apparatus forcontrolling molding conditions for a molding apparatus obtaining amolded product by firmly fitting a molten thermoplastic resin onto amolding surface of a mold under a pressure lower than or equal to 100kg/cm² and curing, said molding apparatus comprising:a mold main body; amold body on which said molding surface is defined; and a space definedbetween said mold main body and said mold body on the back side of saidmolding surface; said controlling apparatus comprising:means forcontrolling introduction and discharge of a fluid into and from saidspace; and pressure control means for controlling pressure of said fluidin said space corresponding to pressure to be exerted onto said moldingsurface, further comprising:heat control means for controlling heatingsaid molding surface from said space on the back side of said moldingsurface to a temperature higher than or equal to Vicat softeningtemperature (T) °C. of said thermoplastic resin, wherein said heating isperformed by heat radiation from a radiation heating device arranged ata position in said space.
 6. A controlling apparatus as claimed in claim5, wherein said radiation heating device comprises a halogen lamp.
 7. Acontrolling apparatus as claimed in claim 1, wherein said controllingcooling includes supplying a cooling fluid into said space at a giventiming.
 8. A controlling apparatus as claimed in claim 7, wherein saidcooling fluid is a liquid state cooling medium, and her comprising meansfor forcedly removing the liquid state cooling medium depositing andresiding on the back side of said molding surface in said space.
 9. Acontrolling apparatus as claimed in claim 1, wherein said cooling isperformed by supplying water or air into said space.
 10. A controllingapparatus as claimed in claim 1, wherein said cooling is performed bysupplying water and air into said space.
 11. A controlling apparatus forcontrolling molding conditions for a molding apparatus obtaining amolded product by firmly fitting a molten thermoplastic resin onto amolding surface of a mold under a pressure lower than or equal to 100kg/cm² and curing, said molding apparatus comprising:a mold main body; amold body on which said molding surface is defined; and a space definedbetween said mold main body and said mold body on the back side of saidmolding surface; said controlling apparatus comprising:means forcontrolling introduction and discharge of a fluid into and from saidspace; and pressure control means for controlling pressure of said fluidin said space corresponding to pressure to be exerted onto said moldingsurface, wherein said pressure control means comprises:first pressurecontrol means for controlling a pressurized fluid supplied into saidspace; second pressure control means for controlling a pressurized fluiddepressing said thermoplastic resin onto said molding surface suppliedon said molding surface side; and pressure adjusting means for followingthe pressure of one of said pressurized fluids to the pressure of theother pressurized fluid.
 12. A controlling apparatus as claimed in claim1, wherein said molding apparatus comprises a blow molding device.
 13. Acontrolling apparatus as claimed in claim 1, wherein said heating isperformed simultaneously or before or after firmly fitting of a parisonutilizing thermoplastic resin onto the molding surface.
 14. Acontrolling apparatus for controlling molding conditions for a moldingapparatus obtaining a molded product by firmly fitting a moltenthermoplastic resin onto a molding surface of a mold under a pressurelower than or equal to 100 kg/cm² and curing, said molding apparatuscomprising:a mold main body; a mold body on which said molding surfaceis defined; and a space defined between said mold main body and saidmold body on the back side of said molding surface; said controllingapparatus comprising:means for controlling introduction and discharge ofa fluid into and from said space; and pressure control means forcontrolling pressure of said fluid in said space corresponding topressure to be exerted onto said molding surface as claimed in claim 1,further comprising:control means for controlling a first fluid pressureapplied into a parison utilizing thermoplastic resin supplied betweenmolding surfaces so as to firmly fit the outer surface of said parisononto said molding surfaces, simultaneously controlling a second fluidpressure applied into said space so as to follow said first fluidpressure, controlling heating of the back side of said molding surfaces,and controlling cooling of the back side of said molding surfaces.
 15. Acontrolling apparatus for controlling molding conditions for a moldingapparatus obtaining a molded product by firmly fitting a moltenthermoplastic resin onto a molding surface of a mold under a pressurelower than or equal to 100 kg/cm² and curing, said molding apparatuscomprising:a mold main body; a mold body on which said molding surfaceis defined; and a space defined between said mold main body and saidmold body on the back side of said molding surface; said controllingapparatus comprising:means for controlling introduction and discharge ofa fluid into and from said space; and pressure control means forcontrolling pressure of said fluid in said space corresponding topressure to be exerted onto said molding surface further comprisingcooling control means for controlling cooling said molding surface fromsaid space on the back side of said molding surface to a temperaturelower than or equal to (Vicat softening temperature (T) of saidthermoplastic resin -10) °C., further comprising:control means forcontrolling an amount of water supplied into said space such that agreater amount of water is supplied to an upper portion of a reverseside of said molding surface than a lower portion thereof.